NUMERICAL AND EXPERIMENTAL THERMAL ANALYSIS OF AL6061 ALLOY FRICTION STIR WELDING

The aim of this research work is to thermally analyze Al6061 alloy friction stir welding (FSW) using numerical and experimental methods. The Infrared (IR) thermometer was used to measure the temperature profile during FSW at various locations of the specimen in the FSW direction. Three-dimensional finite element models were used to investigate the thermal profile in the welding of Al alloy and the heat sources generated due to the friction reaction between the tool shoulder and welded materials. The analysis helps to understand the dynamics of the FSW, the thermal profile along the longitudinal, lateral and through the thickness of welded materials. The experimental results showed that the maximum temperature is directly proportional to the tool rotation speed but inversely proportional to feed rate of the FSW.