Heat transfer in aluminum-steel joint and weld tool during the friction stir welding: Simulation and experimental validation

In this work, dissimilar butt joints of 6061 aluminum and 304 stainless steel were prepared by friction stir welding (FSW), the FSW process is monitored infrared (IR) thermography. Considering different material properties between steel, a novel CFD model with weld tool developed tested to investigate effects on aluminum-steel joint under traverse speeds. The calculated temperature thermal cycles for various speed agreed well corresponding IR thermography experimental results. It found that peak about 10 K lower than measured relative error 2.3%, while it 11.4% without tool. can decrease gradient inhomogeneity field joint. SEM analysis interface showed thickness IMCs may speed. provide viscosity based validated analyze insufficient stirring defect