Simulation of Peak Temperature & Flow Stresses during Friction Stir Welding of AA7050-T7451 Aluminium Alloy Using Hyperworks

To overcome limitations of fusion welding of the AA7050-T7451aluminum alloy friction stir welding (FSW) has become a prominent process which uses a non-consumable FSW tool to weld the two abutting plates of the workpiece. The FSW produces a joint with advantages of high joint strength, lower distortion and absence of metallurgical defects. Process parameters such as tool rotational speed, tool traverse speed and axial force and tool dimensions play an important role in obtaining a specific temperature distribution and subsequent flow stresses within the material being welded. Friction stir welding of AA7050-T7451 aluminum alloy has been simulated to obtain the temperature profiles & flow stresses using a recent FEA software called HyperWorks.; the former controlling the microstruture and in turn, mechanical properties and later, the flow of material which depends up on the peak temperatures obtained during FSW. A software based study has been carried out to avoid the difficulty in measuring the temperatures directly and explore the capabilities of the same to provide a basis for further research work related to the said aluminum alloy.