Abstract
In this work, the effect of tool geometric parameters on thermo-mechanical behaviour in friction stir welding of AA5086 has been investigated. For doing so, the thermo-mechanical responses of material during welding with different tools have been predicted by a three-dimensional finite-element model using the finite-element code ABAQUS. In addition, welding experiments have been carried out to study the developed microstructures and the mechanical properties of welded alloy. The results show that tool geometry significantly affects the energy input, deformation pattern, plunge force, microstructures, and mechanical properties of the joint. The conical tool with the shoulder angle of 2° has been found to produce a larger deformation region as well as higher mechanical properties comparing with the cylindrical tools employed in this research. Additionally, tensile residual stresses are developed within the region around the weld centre-line, which gradually changes to compressive ones beyond the heat-affected zone. It is found that the ratio of heat generation from plastic to friction dissipation in the conical threaded pin is 44 per cent more than the cylindrical pin with similar shoulder diameter.
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