Modeling and Simulation of Friction Stir Welding of Aluminum and Magnesium Alloys Using Finite Element Analysis

The aviation and automobile sectors have witnessed significant expansion and demand for lightweight metals. The friction stir welding (FSW) procedure is used for joining lightweight and low melting temperature materials. A Finite Element Analysis (FEA) utilising COMSOL® Multiphysics 6.0 software is utilised in this article to combine dissimilar metals AA6061-T6 and Mg AZ31-B, and their thermo-mechanical characteristics are explored. The peak temperature was observed to increase to 448K and 928K when the coefficient of friction (COF) increased from 0.01 to 0.4, while other parameters remained constant. When the tool rotational speed is increased to 500, 600, or 700 rpm, the peak temperature climbs to 658 K, 706 K, and 759 K, while all other parameters stay constant. When the welding speed is increased, the peak temperature reduces from 665K, 649K, and 638K to 45mm/min, 60mm/min, and 75mm/min, with all other parameters remained constant in this study. The peak temperature climbed to 632K, 684K, and 759K when the axial force increased to 10 kN, 15 kN, and 20 kN, respectively, which is a tolerable temperature less than the point of melting of materials. Peak temperatures increase to 628K, 630K, and 635K when the shoulder-to-pin diameter ratio increases to 2.5, 3.0 and 3.5 with all other parameters remaining constant. As a result, the peak temperature is directly related to tool rotational speed, coefficient of friction, axial force, and shoulder-to-pin diameter ratio, whereas welding speed is inversely proportional.