Thermo-mechanical simulation of the effect of tool welding speed on butt-joint friction stir welding (FSW) of AA6061
DOI:
https://doi.org/10.38152/bjtv7n4-034Keywords:
friction stir welding, welding speed, temperature distribution, heat affected zone, von-mises stress, thermo-mechanical simulation, finite element methodAbstract
FSW is a welding method that joins pieces of material by rotating a non-consumable pin at high speeds (RPM) while moving it along the weld joint. The combination of this rotation and movement generates heat through friction between the tool and the sheets, facilitating the welding process without the requirement for filler metal. Developed by the British Welding Institute (TWI) in 1991, FSW is celebrated for producing strong, reliable welds and is extensively used in industries such as automotive and aerospace. In these sectors, aluminum alloys are essential due to their unique set of properties, making them highly suitable for FSW applications. In FSW, welding speed refers to the linear velocity at which the tool progresses along the joint line during the welding process. This parameter plays a pivotal role in controlling heat generation, material flow, and ultimately, the quality of the weld. The quantity of heat introduced to the plates directly influences the final weld quality, as well as the residual stresses and deformation observed in the workpieces. This research examines how different welding speeds affect temperature distribution, the width of the heat-affected zone, and the Von Mises stress distribution in welded aluminum alloy 6061 sheets. The aim of this study is to gain a comprehensive understanding of how these factors interact, with the ultimate goal of contributing to the optimization of FSW parameters and improving weld quality. The analysis was performed using finite element method and ALTAIR software, providing valuable insight into the effects of welding speed variations.
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