TWI

A computational fluid dynamics code ("CosmosFlow") was employed to evaluate the temperature distribution in materials during friction stir welding (FSW). Thermal simulations based on finite element models were undertaken to predict the optimum ratio of rotational speed and traverse speed, and results were analysed for FSW of AA-6061-T6 plate (thickness 6 mm). Natural convection and radiation heat transfer mechanisms were considered in the boundary conditions. FSW experiments were performed to measure mechanical inputs such as vertical and longitudinal displacements and forces, rotational speed and torque. The nonlinear relationship between process parameters is discussed with regard to thermal loss effects.

6th International Symposium, 10-13 Oct 2006, Session 9B: Modelling II, Paper 01