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Thermo-mechanical finite element model of friction stir welding of dissimilar alloys

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Abstract

A thermo-mechanical finite element model is developed based on Coupled Eulerian Lagrangian method to simulate the friction stir welding of dissimilar Al6061-T6 and Al5083-O aluminum alloys using different tool pin profiles. The model is validated using published measured temperatures and weld microstructure. The finite element results show that maximum temperatures at the weld joint were below the materials’ melting point. Placing the harder alloy (Al6061-T6) at advancing side led to a decrease in maximum process temperature and strain rate, but increased tool reaction loads. Featured tool pin produced better material mixing resulting in enhanced joint quality with reduced volumetric defects.

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Authors and Affiliations

  1. Mechanical Engineering Department, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia

    Fadi Al-Badour, Nesar Merah, Abdelrahman Shuaib & Abdelaziz Bazoune

Authors
  1. Fadi Al-Badour
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  2. Nesar Merah
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  3. Abdelrahman Shuaib
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  4. Abdelaziz Bazoune
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Correspondence to Fadi Al-Badour.

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Al-Badour, F., Merah, N., Shuaib, A. et al. Thermo-mechanical finite element model of friction stir welding of dissimilar alloys. Int J Adv Manuf Technol 72, 607–617 (2014). https://doi.org/10.1007/s00170-014-5680-3

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  • DOI: https://doi.org/10.1007/s00170-014-5680-3

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