Modeling friction stir welding of titanium and aluminum alloys

Friction stir welding (FSW) is a solid state welding process primarily for aluminum alloys and aerospace applications. However, there is also interest in using FSW for higher temperature aerospace materials such as titanium alloys. In light of this, FSW of Ti-6Al-4V was modeled and compared to aluminum alloys using a finite element model. The model was used to predict the tool and workpiece temperatures for various tool rpm's and plunge rates, as well as loads and deformation behavior. The effect of various tool materials was also examined with respect to tool and workpiece temperature response.