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Effect of Size of Tool on Peak Temperature & Viscosity during Friction Stir Welding of AA6061-T6 Aluminum Alloy Using HyperWorks

K.D.Bhatt Bindu Pillai A.M. Trivedi

Friction stir welding (FSW) of AA6061-T6 aluminum alloy has been attempted to overcome limitations of fusion welding of the same. The FSW tool, by not being consumed, produces a joint with predominant advantages of high joint strength, lower distortion and absence of metallurgical defects. Process parameters such as tool rotational speed, tool traverse speed and axial force and tool dimensions play an important role in obtaining a specific temperature distribution and subsequent viscosity distribution within the material being welded; the former controlling the mechanical properties and later the flow stresses within the material in turn. A software based study to find effect of tool dimensions on the peak temperatures generation during FSW for the said aluminum alloy was carried out to explore the capabilities of the same and provide basis for further research work related to the different aluminum alloys.