Effect of process parameters on temperature and force distribution during friction stir welding of armor-marine grade aluminum alloy

Abstract

This research investigates the effect of process parameters on real-time temperature and forces distribution during friction stir welding of AA7039. Experiments are conducted at different rotational speed, welding speed, and tilt angle conditions. For the experimentation, a low-cost real-time force-measuring fixture is indigenously developed in-house. However, eight K-type L-shaped thermocouples are used to examine the real-time temperature distribution. The forces in the z-direction are of a higher magnitude than the x-direction. The maximum force in the z-direction of 3.25 kN is witnessed for 2° tilt angle and a minimum of 2.1 kN for 26 mm/min of welding speed. The maximum force in the x-direction of 0.97 kN is obtained at 2° tilt angle and a minimum of 0.27 kN is obtained at 1.3° tilt angle. The maximum temperature of 390 °C is observed at 1812 r/min, whereas a minimum of 283 °C is observed at 43 mm/min of welding speed. The variations in temperature and force distribution during friction stir welding are also evaluated by utilizing two phenomenological models.