Finite element modeling of aluminum alloy AA5083-O friction stir welding process

The temperature distribution and the residual thermal stresses generated from friction stir welding process were predicted by using finite element analysis (FEA). The predicted temperature was validated experimentally by using infra-red thermal image camera. Different AA5083-O joints were friction stir welded using cylindrical threaded pin profile and tapered smooth one at different rotational and welding speeds. The increase of welding speed values resulted in lower peak temperature during the welding process and the increase of rotational speed caused higher welding peak temperature. Defect-free welds were obtained by using a threaded pin at lower rotational speed (i.e.400 rpm). All the welded joints by the tapered tool pin profile had internal defects at all welding conditions. The maximum tensile strength of 230 MPa was obtained by using the threaded tool at 400 rpm, 50 mm/min while; the minimum one of 85 MPa was obtained by using the tapered tool at 630 rpm, 100 mm/min.