A three-dimensional numerical analysis of friction stir welding at high speed (HS-FSW) is presented here. The temperature distribution in the workpiece has been calculated for a number of processing conditions. The analysis adopts a thermal model based on the simple laws of friction. This model translates to having a moving heat source along the weld-line on the top surface of the workpieces. Results have been validated experimentally using an infrared camera as well as thermocouple measurements. By comparing actual welds performed on Aluminum 6061-T6 and the numerical predictions, it is observed that the appropriate range for the (maximum) surface temperatures for obtaining a sound weld is between 570°C and 530°C, and that these temperatures are achieved between spindle translation velocities of 125 mm/min and 250 mm/min, respectively.
- Heat Transfer Division and Electronic and Photonic Packaging Division
High Speed Friction Stir Welding: A Computational and Experimental Study
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Raikoty, H, Ahmed, I, & Talia, GE. "High Speed Friction Stir Welding: A Computational and Experimental Study." Proceedings of the ASME 2005 Summer Heat Transfer Conference collocated with the ASME 2005 Pacific Rim Technical Conference and Exhibition on Integration and Packaging of MEMS, NEMS, and Electronic Systems. Heat Transfer: Volume 3. San Francisco, California, USA. July 17–22, 2005. pp. 431-436. ASME. https://doi.org/10.1115/HT2005-72833
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