Temperature Evolution, Material Flow, and Resulting Mechanical Properties as a Function of Tool Geometry during Friction Stir Welding of AA6082

Abstract The friction stir welding process was simulated for joining AA6082 aluminum alloy with the use of the computational fluid dynamics method. Two different tool geometries were used—a tapered cylindrical pin (simple pin) and a hexagonal pin with grooves (complex pin). The analysis of the simulations performed was discussed in terms of temperature evolution during the process, total heat input, residual stresses and material flow. Simulations revealed that a 5% higher temperature, equal to maximum 406 °C, was provided when using the complex pin than with the simple pin. Higher temperature and higher shear stresses during the welding with the complex pin caused the introduction of higher residual stresses in the weld. Experimental results on the produced welds allowed observation of the microstructure of the joints, hardness tests in cross sections and tensile strength tests. Due to the higher temperature during the process with the complex pin and the more efficient recrystallization process, grain refinement in the SZ was more pronounced. The average grain size in the stir zone for the weld produced with the complex pin was equal to 11 ± 1 µm, and in the case of the simple pin 14 ± 1 µm. The presented hardness profiles revealed that the weld produced with a complex pin had higher hardness in the stir zone, equal to 89.5 ± 1.3 HV, which is consistent with the Hall-Petch relationship. The obtained UTS values corresponded to the joint efficiency of 72.5 ± 4.9% and 55.8 ± 8.6% for the weld produced with the complex pin and the simple pin.