Abstract

Friction-stir welding (FSW) is a solid-state joining process (the metal is not melted) that uses a third body tool to join two facing surfaces. Heat is generated between the tool and material which leads to a very soft region near the FSW tool. It then mechanically intermixes the two pieces of metal at the place of the joint, then the softened metal (due to the elevated temperature) can be joined using mechanical pressure (which is applied by the tool), much like joining clay, or dough. In this project we have designed circular tool by using creo-2 and then applied static (tool rotational velocity 1000 rpm) and thermal (temperatures’ and convection on plates and tool also) boundaries conditions And calculated results like deformation stress and heat flux etc. Here I also designed 3 more tools as hexagonal, tapered, truncated and applied the same boundary conditions with same material properties, and calculated all the results. From all these results the truncated tool is the best tool in which maximum stresses produced in fsw process can be minimised. Here I compared two dissimilar tool materials as steel and en9 in which en9 material of truncated tool produces minimum stresses compared to steel truncated tool.

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