Numerical Simulation of Temperature and Axial Deformation during Friction Welding Process between AA6061 and AISI 304 Steel

Abstract

The joining of dissimilar materials is of great importance in automobile industry. In the recent trends, the partial replacement of lightest parts of the automobile components, such as aluminium and magnesium could be joined with steels. In this present work concerns, the numerical simulation of Aluminium (6061) and stainless (304) steel parts is carried out under operating conditions using friction welding process. The optimal process parameters for joining of dissimilar materials are found to be frictional pressure of 30 MPa to 50Mpa, frictional time of 3 sec and rotational speed of 1200 rpm. The result shows that the maximum deformation occurs at the weld interface of dissimilar joints during the optimal process parameter conditions. Also, the peak temperature is observed at the bonding region.