Thermo-mechanical analysis of linear welding stage in friction stir welding: Influence of welding parameters

The influence of friction stir welding parameters on thermo-mechanical behavior of the material during welding is analyzed. An aluminum alloy is considered (Al 2024 T351), and different rotating and welding speeds are applied. The finite element model consists of the working plate (Al alloy), backing plate and welding tool. The influence of the welding conditions on material behavior is taken into account the application of the Johnson-Cook material model. The rotation speed of the tool affects the results. If increased, it contributes to an increase of friction-generated heat intensity. The other component of the generated heat, which stems from the plastic deformation of the material, is negligibly changed. When the welding speed, i.e. tool translation speed, is increased, the intensity of friction-generated heat decreases, while the heat generation due to plastic deforming is becoming more pronounced. Summed, this leads to rather small change of the total generation. The changes of the heat generation influence both the temperature field and reaction force. Also, the inadequate selection of welding parameters resulted in occurrence of the defects (pores) in the model.