Thermomechanical Modeling of Friction Stir Welding for Different Material using Altair's HyperWeld FSW

Abstract

Friction stir welding (FSW) is a solid state welding process which involves the joining of two similar or dissimilar materials without the application of filler material. The tool performs the three steps to complete the welding process which are Plunge, Dwell and Translation. During the plunge stage the tool penetrates into the workpiece material and then translates onto the weld line. In between the translation motion tool moves in forward direction and behind that the workpiece material mixed into each other and form weld. In this paper study, Friction stir welding is a nonlinear thermal process which is simulate with the help of using Altair's HyperWeld. It is foremost computer-aided engineering (CAE) application which used in simulation purpose. Using different materials with different input parameters the butt joint is created. In this study the different materials are used such as AA7075, AA6061, and AA2219 for various process parameters. The process parameters are (1) Rotational speed are 600 rpm, 1000 rpm and 1400 rpm, (2) Tool translational speed are 100 mm/min, 150mm/min and 200 mm/min and (3) Tool shoulder diameter are 12 mm, 18 mm and 24mm. With the help of these different process and geometrical parameters the thermal distribution result is analyzed. The results are presented for dissimilarity in peak temperature of three different aluminum alloy plate at the same input parameters during the Friction Stir Welding process.