Effect of tool rotation speed on thermo-mechanical behavior in dissimilar FSW of 304L stainless steel and Ti–6Al–4V: a FEM-based approach

Key Points

• Thermo-mechanical behavior improves as tool rotation speed changes, enhancing joint quality and strength even in dissimilar materials.
• Key evidence shows that varying the tool rotation speed influences material flow and peak temperatures during welding processes.
• Analysis using finite element method (FEM) reveals the complex interactions between tool speed and thermal properties across different metals.
• This suggests that tuning tool rotation speed may enhance welding performance, with potential applications in various industrial settings.