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Friction Stir Welding (FSW) is a novel solid-state joining process known for its environmentally friendly characteristics, making it a prime example of "green welding." This research explores the experimental investigation and simulation of heat distribution in FSW of AA 6082-T6. An unambiguous non-linear finite element model was developed using ABAQUS software to predict the effects of varying the welding tool's rotational speed on temperature variations and resulting stresses during the plunging, dwelling, and traverse stages. The model was formulated using a coupled Lagrangian-Eulerian technique, with careful consideration of meshing, computational aspects, and mass scaling. Non-linear material properties and heat transfer conditions were also incorporated to account for potential heat loss due to thermal interaction between the tool and the specimen. Coulomb's friction model was employed to simulate the interaction between the welding device and the specimen. The findings indicate that increasing the rotational speed of the welding tool elevates the heat generated and the stresses involved. These stresses play a critical role in the FSW process, influencing the distortion behavior of the welded joints. Same effects are compared experimentally by using different parameters and conditions for producing good quality of joint. Therefore, both experimental and finite element methods can be effectively used to predict the optimal conditions for the FSW process.
Shimpi et al. (Mon,) studied this question.