Friction Stir Welding, Finite Element Modelling, Thermo-Mechanical Modeling

In the present paper, a three-dimensional thermo-mechanical model for friction stir welding is presented. Friction stir welding (FSW) is a relatively new welding process that may have significant advantages compared to the fusion processes. Although originally intended for aluminium alloys, reach of FSW has now extended to a variety of materials including steels and polymers. This study aims to numerically explore the thermal histories and temperature distributions in a work piece during a friction stir welding process involving the butt joining of aluminum 6061-T6. In this regard ABAQUS commercial software was utilized. The process is solid state and as such, temperatures experienced near the weld are lower than those experienced during fusion welding and there are no large density changes due to a solid-liquid transformation.