A three-dimensional fully coupled thermo-mechanical model for Self-reacting Friction Stir Welding of Aluminium AA6061 sheets

In the present work a three dimensional model of self-reacting friction stir welding in aluminium alloy AA6061 has been developed based on the Computational Fluid Dynamics (CFD) approach using COMSOL Multiphysics software. The temperature dependent material properties have been incorporated in the model from available literature. A slip-stick contact between the workpiece and tool surface has been considered with the slip factor varying linearly with distance. The methodology adopted has been validated with experimental results available in the literature. The temperature distribution observed has been found to be asymmetric about the weld centre line. The maximum temperature has been observed on the advancing side of the weld. However, the temperature distribution across the thickness has been found to be almost symmetric about the mid thickness plane. An hourglass shaped temperature distribution has been observed across the cross-section of the weld. The material flow velocity distribution shows that the deformation zone is limited to a very small region around the tool. (paper)