Effect of tool shoulder diameter and pin geometry on temperature distribution in friction stir welding

The contact between the tool and the workpiece is the primary source of heat generation in the welding zone during friction s tir welding. As the welding area accumulates heat, it begins to transfer through the workpiece and the tool. Efficient heat dissipation is required for uninterrupted welding and welding distance extension. A key to this process is the profile and shape of the t ool. We can examine how the heat is dissipated and compare several tools by applying thermal simulations on the tool to observ e how each one would release the greatest amount of heat. In this study, a total of three tools have been designed with differe nt shoulder diameters and pin shapes. These tools were modelled and simulated using Ansys. Subsequently, appropriate mesh sizes and boundary conditions, such as temperature and convection, were established. After meshing the tools, solutions were obtained for all three. Ultimately, it was determined that tool number 3 exhibited the highest heat dissipation at 1070.5. The H13 tool decreases operating temperature by 58.4% in comparison with traditional carbide tools, proving superior thermal management in 304L stainless steel friction stir welding. Future studies should confirm these simulations by conducting controlled friction stir welding tests using Tools 1-3 on AA304L plates while keeping track of temperature with thermocouples and performing mechanical tests. The outcomes will be compared with industrial case histories from industries like aerospace (e.g., joining of SpaceX fuel tanks) and automotive (e.g., Tesla battery tray assembly) where similar tool geometries are employed.