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Mathematical Model to Predict Heat Flow in Underwater Friction Stud Welding

Friction Stud Welding is primarily used to bond different material. Joining of aluminum alloys, stainless steels and composites with any other materials is required in many underwater welding applications. In the present work, a mathematical model has been developed for underwater friction stud welding. A thick AA6061 plate is welded with steel stud in a modified drilling machine. Transient analysis of heat conduction in the plate has been calculated numerically including heat generation due to friction between the materials. The conduction, convective and surface boundary conditions have been considered as per the developed model. Comparison has been made between welding performed in normal atmospheric condition and underwater condition. The temperature distribution in the work piece has been predicted using the developed mathematical model. It is found that there is steep fall in a heat flow during underwater welding condition. High weld strength can be achieved due to less heat affected zone in underwater welding.