Integrating Numerical Simulation and Experimental Validation to Analyze Temperature Distribution in Friction Stir Welding of Dissimilar Aluminum Alloy

This study explores the temperature distribution in Aluminum alloys, specifically AA2024 T351 and AA6351 T6, during friction stir welding (FSW). Utilizing COMSOL Multiphysics software, the research investigates FSW at rotational speeds of 800, 1200, and 1600 rpm, while maintaining a constant welding speed (35 mm/min) and axial force (3 kN). The simulation incorporates temperature-dependent material properties. The findings reveal that the maximum temperature occurs at the upper part of the stir zone for both alloys. Experimental validation demonstrates excellent agreement with the simulated temperature distribution, reaffirming the accuracy of the COMSOL Multiphysics model.