Numerical Simulation of Temperature Field of 6005A-T6 Aluminum Alloy Static Shoulder Friction Stir Welding Based on Adaptive Surface-Body Heat Source Model

Taking the 3 mm-thick 6065A-T6 aluminum alloy plate as the research object, the temperature field and thermal cycle curve of each point in the weld area during the static shoulder friction stir welding process are simulated by ABAQUS software, and the influences of different welding speeds on the peak temperature in the weld area are studied. The results show that with the increase of welding speed, the peak temperature in the center of the heat source decreases gradually, and the area of the high temperature zone of the weld nugget decreases significantly. The cross-section temperature cloud of conventional friction stir welding (FSW) shows a "bowl-shaped" distribution that is wide at the top and narrow at the bottom, while that of the static shoulder friction stir welding is similar to the cone shape of the stirring needle. Under the same process parameters, the peak temperature in the weld zone of static shoulder friction stir welding can be reduced by about 30 ℃ compared with that of the conventional welding process, and its cross-section temperature field is more uniform. The cross-section morphology of the joint observed by metallographic experiment matches with the simulation results, and the temperature field from the finite element is in good agreement with the measured results, which shows that the adaptive surface-body heat source model established can guide and predict the actual welding process.