Analyzing Thermomechanical Characteristics: A Comparative Study of Stationary Shoulder FSW and Conventional FSW

Friction Stir Welding has significantly transformed the metal joining industry, and an innovative variation known as stationary shoulder FSW has emerged. This study aimed to compare various aspects, including force, temperature, and strain, between conventional friction stir welding (CFSW) and stationary shoulder friction stir welding (SSFSW). To accomplish this, the finite element method was employed, utilizing the lagrangian technique to model the welding process. The findings revealed that in SSFSW, the highest temperature was observed in the vicinity of the rotating pin. This was attributed to the absence of a rotating shoulder in SSFSW, which played a major role in heat generation during welding. Moreover, the longitudinal forces on the tool in SSFSW were significantly higher compared to CFSW, approximately ten times greater. In the CFSW process, the affected area showing strain usually forms a basin-shaped pattern. However, in the SSFSW process, the strain distribution is confined within the range of the tool pin.