Finite Element Analysis of Friction Welding Process for Al 6061 and SS 304

The welding of Al 6061 and SS 304 is susceptible to intermetallic layer formation. The interface properties are degraded as intermetallic thickness increases and the formation of intermetallic compounds strongly depends on local temperature attained during the welding process. The formation of intermetallic layer is responsible for brittle failure of components. In the present study a thermo mechanical model was developed to predict temperature distribution and stress during friction welding process of Al 6061 and SS 304. Temperature dependent material properties are taken into account for analysis. The FE analysis results are compared with experimental results.