Simulation of Dissimilar (Al1100-Cu) Friction Stir Welding Using Convection Coefficient Between Workpiece and Backing Plate Based on Its Deformation

Friction stir welding is considered a solution to conventional welding issues, particularly when dissimilar materials are involved. The implication of complex phenomena encourages researchers to utilize numerical simulations in their research. Despite the backing plate being the most significant cause of heat loss, researchers tend to simplify the heat transfer coefficient to the backing plate without considering the deformation pattern of the workpiece. The pressure applied by the tool increases the contact conductance between the workpiece and the backing plate, influencing heat transfer coefficient distribution. This paper aims to model the FSW process involving the deformation of the workpiece. A backing plate in the form of asbestos is employed to capture the deformation of the workpiece on an experimental test. Quadratic polynomial equations are used as an approach to measuring deformation patterns. Based on the results of this study, the coefficient convection distribution based on the deformation pattern produced a temperature history close to the experimental results. Validation of material flow in the model was also carried out.