Using further experimental studies we also propose that another determining parameter in the resulting mechanical properties of FSW welds is the material flow around the tool which in very cold weld conditions may cause low mechanical properties due to low mechanical bonding. Next, based on the current state-of-the-art and a validated 3D thermal model for aluminum 6061 along with a Taguchi design of experiments approach, we make a proposition that hot welds (with maximum temperature during FSW) have the lowest mechanical properties as opposed to cold welds. To this end, in this paper-based dissertation, first we review various models and optimization methods used in the field of FSW. The main objective of this work is the development of a novel integrated multiphysics modeling, testing, and optimization of friction stir welding (FSW) for aluminum alloys, and thereby facilitating a better understating of processing-microstructure-properties relationships in this relatively new welding technique.
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