Design and Analysis of Dissimilar Materials by Friction Stir Welding

Abstract

In a solid-state welding procedure known as FSW (Friction Stir Welding), the workpieces are rotated or moved about one another until the compressive pressures contract, causing the welds to form. Different specimens must be joined together by heat, which is produced at the interface via friction. With a wear-resistant welding tool, heat is generated by friction between the shoulder and the pin. The benefits of friction stir welding come from the fact that it is a special type of weld that doesn't require consumables or special shielding element procedures. The final weld is attractive and flawless.

The goal of this work is to gain a greater understanding of FSW, investigate thermal stresses, and determine temperature distribution using finite element simulation and Abaqus, a program used for both modeling and analyzing mechanical parts. Here, a modeling and simulation approach to examine the characteristics and compatibility of various materials has been done. Thus, when friction stirs welding, the combination of nickel and stainless steel material produces better results than the combination of aluminium and copper material. Additionally, the average heat flux generated by the combination of nickel and stainless steel material is lower than that of the two metals together.