Numerical Modelling and Experimental Validation of Dissimilar Aluminium 2014 and 7075-SiC Composite by Friction Stir Welding

Abstract

In this study, a dissimilar AA7075+25% vol. SiC composite and AA2014 was selected to understand the effect of temperature distribution in the HAZ region with a maximum reinforcement of 25% vol. of SiC in the AA7075 matrix. The friction and slip-stick mechanism were combined in the numerical 3D model and simulated with different process parameters. The peak temperature of the dissimilar aluminium AA7075+25% vol. SiC composite and AA2014 was simulated and predicted as 860 K maximum and 728 K minimum, respectively. The experimental results were obtained in real-time FSW interfaced with a calibrated K-type thermocouple in a DAQ system. The thermocouple was placed at 15 mm, 20 mm, and 25 mm from the weld centerline to obtain experimental temperatures that were extremely close to the numerical peak temperature. The error percentage between the experimental values and simulation values ranged from 2.38% to 13.41%.