RESIDUAL STRESS DISTRIBUTIN FOR FRICTION STIR WELDING IN

Al6061 USING THERMO MECHANICAL ANALYSIS.

C.Ravindiran1, P.Muthukumar2, A.Somasundaram3
1

PG Scholar, Department of Mechanical Engineering, Kongu Engineering College, Erode-52.

Contact No : 9585649373, E-mail id: ravindiranc@gmail.com

2
Asst Professor, Department of Mechanical Engg, Kongu Engineering College, Erode-52.
3
Associate Professor, Department of Mechanical Engg, Kongu Engineering College, Erode-52.
Abstract
In this study, a three dimensional non linear
thermal and thermo mechanical finite element model
of the friction stir welding (FSW) process has been
utilized to study the residual stresses caused by the
thermal cycles. These residual stresses can affect
properties of welded component during service. The
objective is to study the transient temperature,
residual stresses and optimize the welding parameters
like rotational speed, welding speed and axial force to
limit the residual stress of Al 6061. The butt welded
finite element model is developed by using ANSYS
package. The thermal history is predicted from the
thermal model and then sequentially coupled to a
mechanical model that predicts the residual thermal
stresses. The model is three dimensional and uses
temperature dependent material properties. The
model predictions were confirmed with experimental
measurement data (Peak temperature and residual
stress) from previous studies.
Keywords: Friction stir welding, Transient
temperature, Residual stress, Thermo mechanical
analysis

1.

Introduction

Friction stir welding (FSW) is a solid

state joining process patented by The Welding
Institute (TWI) in 1991. This metal joining
technique is derived from the conventional
friction welding. In a typical FSW, a rotating
cylindrical pin tool is forced to plunge into the
plates to be welded and is moved along their
contact line. During this operation frictional

heat that is generated by contact friction

between the tool and work piece softens the
material. The plasticized material is stirred by
the tool and forced to flow to the side and the
back of the tool. As the temperature cools
down, a solid continuous joint between the
two plates is then formed. Because the highest
temperature in the FSW process is lower than
the melting temperature of the workpiece
material. Consequently, undesired parameters
resulted from typical welding processes will
not materialize. Some of these parameters are
solidification cracking, liquidation cracking
and porosity. However, the motion constraints
imposed by the rigid clamping of the weld
pieces can lead to significant rise in residual
stresses.
Residual stresses in welded metals play
an important role in understanding the
response of a friction stir welded structure
subjected to general loading as well as its
fatigue crack growth resistance [4].
To date, most of the researchers focused
their attentions on the heat transfer or
Temp
(C)

K (W/mK)

Cp
(Kg/m3 E (GPa)
(J/KgK)

162

917

2703

69.7

93.3

177

978

2685

66.2

204.4

192

1028

2657

59.2

315.6

207

1078

2630

47.8

427.7

223

1133

2602

31.7

571.1

253

1230

2574

temperature analysis [1] and strength

properties of FSW [2]. Nandan et al. [4]
investigated the variations of heat energy and
temperature produced by the FSW they point
that only about 5% of the heat generated by
the friction process flows to the tool and the
rest flows to the workpiece. David and Feng
[3] proposed a simple heat transfer model for
predicting the temperature distribution in the
workpiece of the FSW. Most currently, Donne
et al. [2] reported the measured residual
stresses in friction stir welds for2024-T3 and
6013-T6 aluminums.
The present paper conducts threedimensional nonlinear thermal and thermomechanical simulations for the FSW of Al6061
using the finite element analysis. A finite
element package, ANSYS was used for the
computations. The results for both transient
temperature and residual stresses are
compared with the available experimental data
to validate the present simulations.
Model description:
In the welding process the travel speed
is 40mm/min and rotational speed is 1400rpm.
The welded plates are Al6061-T6 alloy, each is
in rectangular shape with a size of (200*50*6
mm). The rotating tool is considered as rigid
solid, and the weld plate is considered as
ductile material characterized with elasticity,
plasticity and kinematic hardening effect. The
material properties related to the various
temperatures are given in table 1
Table 1 Material properties of Al6061-T6 related
to temperature.

Assumptions:
A Number of assumptions have been
made in developing the finite element model,
which includes:

Workpiece material is isotropic and

homogeneous.

No melting occurs during welding

process.

Thermal boundary conditions are

symmetrical across the weld centreline.

Heat transfer from the workpiece to

the clamp is negligible.

The symmetry planes are applied on

lateral sides of the work piece.

Governing equations:
Three-dimensional partial differential
equation for heat conduction in solid is given
as,

-------- (1)
Where T is the temperature, c is heat capacity,
r is the density and kx, ky, kz are thermal
conductivities along three directions. Local
heat generated (dQ) between shoulder and
work piece surface on an elemental area from
a distance (r) can be calculated as
dQ = 2Fnr2dr

---------- (2)

Coefficient of friction () varies with

temperature. Fn is axial load normal to
shoulder and is angular velocity of tool.
Finite element model:
In the present thermal analysis, the
workpiece is meshed using a brick element
called SOLID70 shown in Fig.1. The element
is defined by eight nodes with temperature as
single degree of freedom at each node and by
the orthotropic material properties.

Fig. 1. Finite element mesh of weld plate Al6061.

Results:

Fig. 3. Temperature profiles when tool penetration

reaches middle portion of the plate.

The isothermal profile in the mid

section of the plate for various time intervals
is shown in Figs. 2-5. The peak temperature is
varying with time as the tool moves. The
temperature profiles at different timings are
analyzed individually.

Fig. 4. Temperature distribution when

tool penetration ending.

Fig. 2. Temperature profiles when tool start to

penetrate.

Fig. 5. Temperature Profiles over the Span of 90

Seconds to validate the simulated results

In residual stress calculation, FSW fixture

release was included when temperature cool

down to room temperature. The residual
stress distribution is shown in Figs. 6&7.
[2]
[3]

[4]

Fig. 6. Residual stress distribution.

[5]

[6]

Fig. 7. Residual stress distribution to validate the

simulated results.

Conclusion:
A couple field analyses have been
performed to study the thermal history and
stress distribution in FSW of aluminum alloy
6061-T6. Largest residual stresses are
expected along longitudinal direction and
close to the weld zone. Magnitude of residual
stress in welded specimen is proportional to
its process parameters.
References:
[1] W.M. Thomas, E.D. Nicholas, J.C.
Needham, M.G. Murch, P. Temple-

Smith, and C.J. Dawes. Friction Stir

Butt Welding, International Patent
Application No. PCT/GB92/02203,
1991.
C.J. Dawes and W.M. Thomas,
Friction Stir Process Welds Aluminum
Alloys, Weld. J., 1996, 75, p 4152 .
S.A. David, T. DebRoy, J.C. Lippold,
H.B. Smartt, and J.M. Vitek, Ed.
(Materials Park, OH, USA), ASM
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R. Nandan, T. DebRoy, and H.K.D.H.
Bhadeshia, Recent Advances in
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