Mathematical Model for Analytical Estimation of Generated Heat During Friction Stir Welding - Part 1

Abstract

Heat generation controlling is a prerequisite for a high-quality welds creation during friction stir welding (FSW) processes and it is important to have an adequate mathematical model that is capable of estimating heat generation during FSW with satisfying accuracy. There are numerous models that do explain heat generation and give results with various degrees of accuracy, but these models include numerous approximations and neglect some key parameters for heat generation. The main objective of this work is to provide an accurate mathematical model for heat generation estimation. Mathematical model given in this work describes/defines contact condition, contact pressure, friction coefficient, thermal history of the welding plates and points out the dual nature of heat generation process in FSW adhesion and deformation component in total heat generation. Generated heat, estimated by the mathematical model, is compared with the experimental power. It is concluded that this new algorithm for heat generation estimation gives. applicable results and furthermore that adhesion component of total generated heat dominates though deformation component should not be neglected in the estimation of the generated heat.