Influence of Tib2 Reinforcement and Tool Traverse Speed on the Structural and Thermal Behavior of Dissimilar Metals (AA7075–AA2024) of Friction Stir Welded Joints: an ABAQUS Study

Friction Stir Welding (FSW) is a modern solid-state joining technique known for its energy efficiency, strong joints, and minimal environmental impact. This project focuses on joining two dissimilar high-strength aluminium alloys AA7075 and AA2024 using the simulation software ABAQUS. The welding was performed on the plates measuring 200 mm in length, 60 mm in width, and 6 mm in thickness. In this study, a Finite Element (FE) simulation was performed to understand the structural and thermal behaviour during welding. Various process parameters were tested, including tool rotational speed, feed rate and tilt angle to identify the most effective settings for achieving strong and defect-free joints. The simulation showed that the welding parameters were Tool speeds of 1000,2000 and 3000 rpm; Feed rates of 1,2 and 3 mm/sec; Tilt angles of 10,1.50 and 2°. These parameters produced in a moderate peak temperature of approximately 580°C, which is within the ideal plasticization range for both AA7075 and AA2024 without exceeding their melting points. This ensures proper material flow, defect-free weld formation, and maintenance of the mechanical properties.