Numerical Simulation of Friction Stir Spot Welding of Aluminium-6061 and Magnesium AZ-31B

Abstract

.The friction stir spot welding process is a solid-state joining process that has attracted significant attention due to its ability to join low melting point lightweight alloys such as aluminium and magnesium with high efficiency. A numerical simulation study was performed using ABAQUS finite element software to understand the complex thermo-mechanical joining process involved with friction stir spot welding. The simulation primarily aims to interpret the effect of a set of process parameters and tool geometry on the workpiece plates. Johnson-Cook damage criteria model was used to obtain the stress, and strain distribution on the workpiece consisting of Aluminium 6061 and Magnesium AZ-31B placed in a lap configuration. The workpiece's temperature distribution was obtained by simulating a penalty-based frictional contact between the tool and the plate. The thermal results showed that the maximum temperatures attained were significantly lower than the melting points of the base materials indicating that the material mixing and joining occurred due to the superplastic deformation process instead of melting. The model also observed a change in material flow behaviour as pin and shoulder geometries changed. © 2022 Trans Tech Publications Ltd, Switzerland.