Investigation of the Effect of Heat Transfer during Friction Stir Welding (FSW) of AZ80A Mg Alloy Plates using a Pin Tool by Conducting Finite Elements Analysis

Abstract

Friction stir welding (FSW) is an innovative solid-state welding process that has attracted substantial attention due to its potential for combining problematic materials such magnesium alloys, such as AZ80A. In order to better understand the impact of heat transport during FSW of AZ80A magnesium alloy plates using a pin tool, this study used finite element analysis (FEA). The welding process's thermal features, such as temperature distribution, thermal stresses, and material flow patterns, are the major focus of this analysis. The first step of the study is to conduct a comprehensive literature evaluation to lay a firm groundwork and pinpoint knowledge gaps. The thermal conductivity, specific heat, density, and mechanical characteristics of AZ80A magnesium alloy are measured and recorded as part of the material characterisation process. To ensure an exact simulation of real-world welding circumstances, a comprehensive 3D model of the welding setup is built, including the AZ80A magnesium alloy plates and the pin tool. In order to accurately record temperature variations, a tiny mesh is used, particularly in the welding zone. By include boundary conditions that mimic the real-world welding characteristics, such as the rotation of the pin tool and the clamping or fixturing of the plates, finite element analysis is used to model the FSW procedure. To simulate the heat input produced by FSW, a heat source or heat production model is used.