Heat generation, plastic deformation and residual stresses in friction stir welding of aluminium alloy

The interactions among thermal history, plastic deformation and residual stresses in the friction stir welding (FSW) process under different parameters have been widely considered a crucial issue still not fully understood. In present study, novel three-dimensional coupled thermo-mechanical finite element (FE) model based on Coupled Eulerian-Lagrangian approach (CEL) has developed to simulate FSW of aluminium alloy AA 6082-T6 analyse interaction mechanisms conditions. numerical successfully simulates plunge, dwell, steps captures evolution temperature, deformation, welded joint. obtained results were validated by experimental testing with observed cross-weld optical macrography stress measurement using neutron diffraction technique. reveal that tool rotation speed governs temperature evolution; peak increased from 740 850 °K when rose 800 1100 rpm. rotational also affected material flow, volume being stirred during process. Higher is formed stirring zone increasing angular velocity. This behaviour led an increase effect tool, reduction tunnel defect size enhancing quality weldments. distribution zones joints found M-shaped profile. A significant tensile characterised edge nugget both longitudinal transverse directions, balanced compressive thermo-mechanically zone, heat-affected base metal. presented FE modelling provides reliable insight into effects weld optimisation minimised trials.