Finite element approach in thermal modelling of friction stud welding

Friction stud welding is one the solid state joining process which is produced by means of converting mechanical energy to thermal energy at the interface of the samples by without any external means. Since heat is produced during the welding, the study of thermal behavior on the materials is required. In this paper a one dimensional heat modeling was produced based on the micro annulus approach. The heat flux values are generated by means of heat energy and torque. In this approach on increasing the rotational speed and the pressure the heat values of heat flux increased. Thus the heat flux is proportional to the rotational speed and the pressure. Also the AA6061 and SS304 was welded by considering the indermediate process paprameters like rotational speed, frictional pressure, upsetting time and friction time. The temperature distribution was calculated by means of Finite Element Approach, based on steady and unsteady condition. The heating curves and the cooling curves are to be plotted based on the material properties obtained on steady and unsteady states. The temperature distribution helps to validate it with the experimental values and it is found that the unsteady state condition is more accurate and stable than the steady state condition. Thus the unsteady condition is more suitable and the thermal conductivity of the material plays a major role in the temperature distribution.