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Simulation and Calculation of Peak Temperature in Friction Stir Welding Process of Aluminium Plates


Mayur Shivajirao Patil , VJTI, MUMBAI, INDIA; Dr.S.A.Mastud, VJTI,MUMBAI


Comsol Multiphysics, FSW, Steady State Model, Thermal Profile


The main objective of this paper work is to optimize the welding parameters such that the maximum temperature in the work piece material reaches up to 80-90% of melting point of base material in friction stir welding of aluminum plates. Friction stir welding (FSW), invented and established by The Welding Institute (TWI) in 1991 amongst the emerging new welding technologies, is used frequently for welding of high strength aluminum alloys which are difficult to weld by conventional fusion welding techniques. Friction stir welding (FSW) is a relatively new welding process that may have significant advantages compared to the fusion processes as follow: joining of conventionally non-fusion weldable alloys, reduced distortion and improved mechanical properties of weldable alloys joints due to the pure solid-state joining of metals. The study of microstructure and flow of material around the welding tool during friction stir welding (FSW) is closely linked to many of the key issues related to the process. The heat source in this model is the friction between the material and the probe and the shoulder. For understanding the FSW thermo mechanical process, the thermal history in the friction stirred weld is simulated numerically. It is necessary that the model can be further to optimize the FSW process in order to minimize peak temperature within process window. The welding process was simulated using COMSOL MULTIPHYSICS software and developed thermal profile. Modeling and simulation of FSW has been a great challenge due to the complexity of the process. The results clears that an increase in the rotational speed and coefficient of friction causes increase in the peak temperature in workpeice. The simulation result is compared to available experimental results. According to results in steady state model, when tool is at center in process the temperature is not maximum at center but slightly front of the tool, this is due to preheating in the workpeice.

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Manuscript Id :IJSTEV2I1001
Published in :Volume : 2, Issue : 1
Publication Date: 01/08/2015
Page(s): 6-12
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