Finite element analysis of friction stir welding process to predict ­temperature distribution

ABSTRACT

Friction Stir Welding (FSW) is a solid-state joining technique which attained significant awareness due to its ability to produce high-quality welds without melting the base materials. The distribution of temperature across the plates during the FS Welding process is critical for determining the microstructural evolution, mechanical properties, and residual stresses of the welded joints. This research article aims to develop a comprehensive finite element (FE) model to predict the temperature distribution during the FS Welding process. The FE model incorporates the coupled thermo-mechanical behaviour of the FS Welding process, considering the heat generation and temperature-dependent material characteristics, plastic deformation and friction, and also the effect of tool geometry. The model is validated using experimental measurements, and the results obtained shows the simulated values representing the highest temperature obtained with respect to experimental values are within an error percentage of 3% from the experimental values and thereby validating the FEA procedure.

Keywords:
Finite element (FE) model; Solid-state joining technique; Friction Stir Welding; Measurements; Mechanical behaviour