Profile Optimization in Tooltip for FSW Process—A Numerical Investigation

Friction Stir Welding (FSW) is employed for welding the metal surfaces without changing their phase. The major process variables of FSW are the profile of tooltip including plain or grooved surfaces, rotary speed of the tooltip, the angle of the tool fixed, and the vertical force on the tooltip. This investigation focuses the tooltip geometry with plain surface in FSW of AA6061. Initially conventional cylindrical profile is considered with a predefined tool spinning speed of the tool and compressive force which applied over it axially, for a specific welding application. The factors varied four levels. The stability related, thermal, and transient investigations were performed. The observations were compared with different geometries including two different truncated cone profiles and a hexagonal prismatic profile. The best profile suggested based on the investigation results.