Parametric study of transient temperature distribution in FSW of 304L stainless steel

Three-dimensional nonlinear thermal simulations are carried out for the friction stir welding (FSW) of 304L stainless steel using finite element analysis software—COMSOL® Multiphysics. Based on published experimental data of transient temperature for the Stainless Steel 304L, the thermal numerical simulation is verified. Cases of parametric sweeps for a few important welding parameters like normal force (5–50 kN), rotational speed (200–1500 RPM), shoulder radius (10–50 mm), and translational speed (0.5–3 mm s−1) are analyzed at three specific locations for the friction stir welding process. The objective of this analysis is to study the effect on transient temperature during the welding operation with varying parameters. The validated model is extended to parametric study of variation of transient temperature with shoulder radius and normal force that have not yet been experimentally validated. Transient temperature is an important factor for successful fusion of metal. The simulation shows an increasing trend of the peak temperature with increasing tool rotational speed, decreasing travel speed, increasing shoulder radius, and increasing normal force. This analysis can assist in choosing optimum welding parameters for successful welding under various constraints and for prediction and control of heat-affected zone.