Analysis of Friction Stir Welding Utilizing ANSYS: A Study Based on Simulation

Year : 2025 | Volume : 03 | Issue : 02 | Page : 62 77
    By

    Sumit Joshi,

  • Mridul Gupta,

  • Nitin Nautiyal,

  • Kavi Bhushan,

  • Shashank Joshi,

  • Manan Sawhney,

  1. Assistant Professor, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, Rohini Sector-22, New Delhi, India
  2. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, Rohini Sector-22, New Delhi, India
  3. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, Rohini Sector-22, New Delhi, India
  4. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, Rohini Sector-22, New Delhi, India
  5. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, Rohini Sector-22, New Delhi, India
  6. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, Rohini Sector-22, New Delhi, India

Abstract

Friction Stir Welding (FSW) represents a sophisticated solid-state welding methodology that has attracted considerable scholarly attention due to its efficacy in amalgamating high-strength, lightweight substrates including aluminium, magnesium, and titanium alloys. FSW enables the fabrication of defect free products with a substantial amount of mechanical and wear properties. The process is highly sensitive to various parameters that significantly influence the quality and strength of the final product. Studies have shown that FSW parameters—such as tool rotational speed, tool traverse speed, tool geometry and features, tool tilt angle and axial load—must be carefully optimized to ensure defect-free joints and superior performance. Study shows that the FSP parameters such as tool rotational speed, tool traverse speed and tool features should be selected optimally in order to achieve defect free products. FSW fabricated products are broadly used in aerospace, automotive, marine, and defense industries for producing lightweight, high-strength, and defect-free structures. They are also used for surface modification, grain refinement, and developing composites with superior wear and corrosion resistance. The present study encompasses a comprehensive examination of the FSW procedure utilizing ANSYS, a leading software platform for engineering simulations. The primary objective of this investigation is to explore the thermal, mechanical, and material flow attributes inherent in the FSW technique, thereby elucidating the temperature distribution, stress profiles, and material deformation phenomena. Through the simulation of varying FSW
parameters such as tool rotation velocity, welding speed, and tool configuration, this analysis endeavours to elucidate their impacts on the quality and integrity of the weld joint. The outcomes derived from the ANSYS simulation afford a holistic comprehension of the critical determinants influencing weld formation, encompassing heat generation, the heat-affected zone (HAZ), and the potential for defect occurrence. This inquiry underscores the merits of employing computational modelling to refine the FSW process, mitigate the necessity for trial- and-error in experimental frameworks, and foresee the performance metrics of welded connections. The results contribute to an enriched understanding of FSW dynamics, facilitating the advancement of enhanced welding methodologies for both conventional and innovative materials.

Keywords: FSW, ANSYS, Materials, Friction Stir Welding, Smulation

[This article belongs to International Journal of Mechanical Dynamics and Systems Analysis ]

How to cite this article:
Sumit Joshi, Mridul Gupta, Nitin Nautiyal, Kavi Bhushan, Shashank Joshi, Manan Sawhney. Analysis of Friction Stir Welding Utilizing ANSYS: A Study Based on Simulation. International Journal of Mechanical Dynamics and Systems Analysis. 2025; 03(02):62-77.
How to cite this URL:
Sumit Joshi, Mridul Gupta, Nitin Nautiyal, Kavi Bhushan, Shashank Joshi, Manan Sawhney. Analysis of Friction Stir Welding Utilizing ANSYS: A Study Based on Simulation. International Journal of Mechanical Dynamics and Systems Analysis. 2025; 03(02):62-77. Available from: https://journals.stmjournals.com/ijmdsa/article=2025/view=228039


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Regular Issue Subscription Original Research
Volume 03
Issue 02
Received 20/08/2025
Accepted 16/09/2025
Published 26/09/2025
Publication Time 37 Days
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