Publication

Abstract : A two-dimensional steady state visco-plastic model has been developed for friction stir welding of dissimilar metals using a commercial CFD code, FLUENT®. Volume of Fluid (VOF) approach is used to model the welding process of dissimilar metals. Initially, the model developed is validated against experimental measurements of Peel et al. (Metall Mater Trans A 37 A:2183–2193, 2006). Simulations were done for two different material combinations, AA 5083–AA 6061 and AA 2024–AA 7075. The temperature distribution and material flow around the tool is studied for different position of materials, process parameters, and tool profiles. It is seen that the peak temperature is generated on harder material side with change in position of materials. This is mainly because on harder material side more heat is generated due to viscous dissipation. The trivex pin profile is found to be better than circular pin profile by reducing welding traverse force and an efficient symmetric mixing of materials. © 2015, Springer-Verlag London.