Influence of tool rotational speed in butt-joint friction stir welding (FSW): a thermo-mechanical simulation of AA6061

Friction Stir Welding (FSW) is a solid-state welding technique that involves joining two pieces of material by rotating a non-consumable pin at high RPM. This rotation generates heat through friction between the tool and the plates, enabling the welding process without the need for filler metal. Invented by the British Welding Institute (TWI) in 1991, FSW is renowned for creating strong welds and is widely used in the automotive and aerospace industries, in those industries the aluminum alloys are indispensable due to their unique combination of properties. This study focuses on how variations in rotational speed influence temperature distribution, the width of the heat-affected zone, and Von-Mises stress distribution in welded aluminum alloy 6061 sheets, this research aims to provide a comprehensive understanding of these effect, therefore the findings are expected to contribute to optimizing FSW parameters and enhancing weld quality. The analysis was conducted using the finite element method and ALTAIR software.