Three Dimensional Transient Analytical Modeling of Friction Stir Welding (FSW) Including Actual Affected Parameters

Welding is highly reliable and efficient metal joining process. In welding the metal adjacent to the weld joint is subjected to severe thermal conditions. As a result, complex changes in metallurgical structure occur in this region. These changes in structure depend on the material and the temperature history experienced. Friction stir welding (FSW) is relatively a new welding process in which, heat is generated by friction between the tool and the workpiece. The amount of heat conducted into the workpiece determines the quality of weld, residual stress and distortion of the workpiece. The objective of the current work is to study the transient temperature in a friction stir welding. So, a three dimensional transient analytical model is used to study the thermal distribution during the welding. Heat input from the tool shoulder alone is considered in the model. The process parameters like axial load, welding speed and tool rotational speed, used in actual FSW process are taken to build the model. This analytical model is very useful for select the optimized affected parameters in friction stir welding. The model illustrates the comprehensive equation including actual affected parameters in FSW and it can be used for different materials. In addition to the above the thermal history finds application in design of welding tools.