Prediction of 3-dimensional heat treatment model during the friction stir spot welding of AA 6061

In this research work, a die steel tool was used to join the two aluminium sheets together on a radial drill machine. For this, a cylindrical-shaped tool was fabricated. This tool is then clamped into the drill machine tool post. This rotating tool is then inserted/indented into the workpiece thus generating heat due to friction. The of the deformation of aluminium starts near the vicinity of the die steel tool impression. The tool transferred the soft material from the tip to the plunger. The plunger is in contact with the Aluminum sheet. Soften material is forged on the sheet with the help of a plunger and thus creating a solid phase joint between the Aluminum sheets. Three-dimensional numerical modelings were performed on Ansys software. A 3-D heat transfer model was used to solve the problem of friction stir spot welding (FSSW). This model was solved by applying the energy conservation equation. This model involves the heat generated at the boundary of the workpiece (AA) and the rotating tool and for study, the problem, steady-state heat transfer equation was used. The numerically computed and the measured values are compared to validate the results.