Simulation and Experimental Study on Weld Temperature in FSW of AA5083

Abstract

Friction Stir Welding (FSW) is one of the solid-state welding process, where a rotating non-consumable tool is used to unite two materials via stirring action and plastic deformation of the material. The aim of the work is to develop thermal numerical model of FSW for obtaining the Peak Temperature. In this process the peak temperature is the property which affects microstructure and mechanical properties of the Welded product. Rotational speed, welding speed, tool design etc. are the welding parameters of the Friciton Stir Welding process that are to be controlled so that the quality of weld can be obtained as desired. Finite Element modelling is carried using ABAQUS software. The simulation is successfully carried out for the plunging and welding stage of the Friction stir welding. The temperature data were taken at the point where the thermocouple is to be kept during the physical welding process. The temperature found at the nugget zone was less than the melting point temperature of the parent material. The experimental work was been carried out and the temperatures during the experiment was noted through the thermocouples using the data logger and it was also found that there is no melting at the nugget zone during the experiment also. The temperature data obtained through thermocouple and through the simulation were compared and the error was found in the range of 1.5% to 7.5% which states that the simulations are in good agreement with the experiments data. Tensile test of the weld samples were taken and was found that the higher strength was obtained using the highest rotational speed with the lowest traverse speed.