Computational Study of Metal Flow Behavior of AA 6061 in Friction Stir Processing with Twin Tools

Vineet Kumar Tiwari, Akshoy Ranjan Paul, Anuj Jain*, Somnath Chattopadhyaya, Sachindra Shankar, Pedro Vilaca

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contributionScientificpeer-review


In order to tackle the growing demand of low weight to strength ratio materials in shipbuilding, trains, and aerospace applications, high strength aluminum alloys have shown good promise. Fabrication of parts with aluminum alloys has always been a challenge as conventional welding processes, which are basically fusion welding techniques, are not able to provide enough joint strength against impact. Friction stir welding (FSW) that generates heat from friction between a rotating tool and work-pieces to be welded, has shown promise to provide better strength. One of the important parameters that dictate the strength of joints produced by friction stir welding is the amount of mixing. Research has been carried out to improve mixing by modifying the tool geometry by several scholars. The present work is focused on improving mixing using twin tools instead of a conventional single tool. Numerical analysis is carried out using a finite volume method based computational fluid dynamics (CFD) solver. The result reveals that twin tools in linear alignment in the direction of welding with the rear/follower tool rotating in a direction counter to the front one can improve mixing as well as even distribution of material, leading to stronger joining.

Original languageEnglish
Title of host publicationAdvances in Manufacturing Engineering and Materials II - Proceedings of the International Conference on Manufacturing Engineering and Materials, ICMEM 2020
EditorsSergej Hloch, Dagmar Klichová, Frank Pude, Grzegorz M. Krolczyk, Somnath Chattopadhyaya
Number of pages6
ISBN (Print)9783030719555
Publication statusPublished - 2021
MoE publication typeA4 Article in a conference publication
EventInternational Conference on Manufacturing Engineering and Materials - Nový Smokovec, Slovakia
Duration: 21 Jun 202125 Jun 2021

Publication series

NameLecture Notes in Mechanical Engineering
ISSN (Print)2195-4356
ISSN (Electronic)2195-4364


ConferenceInternational Conference on Manufacturing Engineering and Materials
Abbreviated titleICMEM
CityNový Smokovec


  • Computational fluid dynamics (CFD)
  • Friction stir welding (FSW)
  • Mixing
  • Twin tool


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