An analytical model of heat generation for eccentric cylindrical pin in friction stir welding

An analytical model for heat generation for eccentric cylindrical pin in friction stir welding was developed that utilizes a new factor based on the tool pin eccentricity. The proposed analytical expression is a modification of previous analytical models from the literature, which is verified and well matches with the model developed by previous researchers. Results of plunge force and peak temperature were used to validate the current proposed model. The cylindrical tool pin with eccentricities of 0, 0.2, and 0.8 mm were used to weld two types of aluminum alloys; a low deformation resistant AA1050-H12, and a relatively high deformation resistant AA5754-H24 alloy. The FSW was performed at constant tool rotation speed of 600 rpm and different welding speeds of 100, 300, and 500 mm/min. Experimental results implied that less temperature is generated using eccentric cylindrical pin than cylindrical pin without eccentricity under the given set of FSW process conditions. Furthermore, numerical simulation results show that increasing the pin eccentricity leads to decrease in peak temperature.