This thesis presents a FSW modelling of temperature using ANSYS APDL 16.2 (Ansys Par-ametric Design Language). It intends to predict the thermal distribution by taking into ac-count different thermal variation imposed by different backing plate material. The effect on the cooling rate, and peak temperature was studied using finite elements analysis (FEA) tech-niques. For more validity the simulation’s results were compared with temperature data ac-quired experimentally under similar conditions.

A thermal transient modelling of friction stir welding were developed, by considering a moving heat source was considered. The heat input was obtained from the friction between the tool shoulder with the workpiece in the heat transfer analysis. The heat flux is calculated in the finite element analysis model considering the heat input generation from the tool’s shoulder and probe.

An accurate temperature measurements during FSW process is a challenging task for ex-perimental measurements since it performed using thermocouples type K that embedded into the workpiece and the (TWT) tool-workpiece thermocouple to measure temperature during FSW.[1]. The peak temperature and cooling rate in different positions were registered for welds using different backing plate materials with different thermos conductivities.

By the data analysis, it was verified that the backing plate material diffusivity affects the peak temperature and cooling rate. On both, simulation and experimental results, the temperatures were higher when a material with lower thermal conductive was used as backing plate. The experimental results have validated the model, in both peak temperature and the cooling rate.