Experimental and Numerical Investigation of Tool Heating During Friction Stir Welding Experimental and Numerical Investigation of Tool Heating During Friction Stir Welding
Experimental values for the heat input to the tool ranged from 155 W to 200 W, comprising 2.8% to 5.1% of the total mechanical power. Regression equations developed for the two values show that each is a function of the process operating parameters. Heat conduction models of the tool show that the approximate spatial distribution of the heat input to the tool along the tool/workpiece interface is one where the heat input is distributed non-uniformly along the interface, with 1% entering the tool at the pin, 20% entering at the base of the pin, and the remainder entering the flat portion of the shoulder. This distribution was valid for the majority of process operating parameter combinations tested. The maximum predicted temperature for the simulations occurred in the pin. This result was verified by the experimental tool temperature measurements. Insights gained into the FSW process from the combined experimental/numerical investigation were then discussed.
School:Brigham Young University
School Location:USA - Utah
Source Type:Master's Thesis
Keywords:friction stir welding tool heat input numerical modelling transfer design of experiments aluminum conduction
Date of Publication:07/12/2005