Numerical Simulation of Heat Transfer Behavior of Dissimilar AA5052-AA6061 Plates in Fiction Stir Welding: An Experimental Validation

Abstract

Fiction Stir welding (FSW) a unique type of metal joining process in solid state, where the heat generation takes place due to the friction action between the rotating tool and the work piece. It is generally used to join all series of Aluminum alloys with good strength and other metallic alloys finds difficult to weld through regular fusion welding techniques. The metal joining takes place in the solid state as the metal to be welded reaches about 80% to 90% of its melting temperature. The joining of metals in friction stir welding does not require any filler metals all classes of Aluminium alloys can be joined and in some desirable cases dissimilar metal compositions and Aluminiun metals composites can be joined satisfactorily. Joining of dissimilar metals has become a trend in the industries like aerospace, automotive chemical etc. as the helps in reducing the cost incurred by eliminating the costly materials. In the present study an experimental investigations are made to study the heat transfer behavior by determining the temperature distribution in AA5052-AA6061 plates during the Friction Stir welding. A three dimensional transient analysis is made by using ANSYS finite element analysis software. Thermocouples are placed at the suitable locations and the same point the temperature readings were taken from the simulation results. The experimental data is compared with the numerically simulated results. The numerical simulations results obtained are in better agreement with the experimental data obtained.

Keywords

• friction stir welding
• dissimilar metals
• aluminum alloy series
• heat source model
• transient analysis