A Finite Element Simulation on Effect of Different Tool Profiling on FSW
Friction Stir Welding (FSW) is a new solid-state welding technique that finds application in various industries. It involves the joining of metals without any help of fusion or filler material. The joint between two metals can be formed through the combined action of frictional heating and mechanical deformation, which is developed due to a rotating tool. The friction act like a heat source that provides sufficient heat to stir the material. The material that flows around the tool undergoes an extreme level of plastic deformation. Rotation generates enough friction and the friction generates sufficient heat to plastify the material. Friction Stir Welding (FSW) is used for welding aluminum alloys. However, interest is growing in utilizing the process in a wider range of applications that also employ non-aero engine metallic materials. Therefore, it is the objective of this paper is to provide a broad view of the capabilities of the FSW process for joining metals and also gives sense when welding is performed with different tool profile and rotational speed. This work will cover the basics of the process and the fundamental aspects of operating an FSW. This includes a description of the different parameters that have been involved in this process and also their effect when parameter changed in form of tool geometry and rotational speed.