Friction stud welding is a solid-state process in which the heat for welding is produced by direct conversion of mechanical energy to thermal energy at the interface of the components without the application of electric energy or heat from other external sources. Since it is thermal energy process, study of thermal behavior of dissimilar metals during friction stud welding process is important. Though there exist many thermal models for friction welding process, there is no suitable thermal model for friction stud welding process. The present study considers a continuous heat source in a short slender cylindrical rod with one dimensional heat flow. A mathematical model is used to predict the heat flux generated at the interfacial region of the two dissimilar metals. Heat loss from the tip of the short slender cylindrical rod is considered as adiabatic and heat lost by radiation is assumed to be negligible. Applying the first law of thermo dynamics and Fourier’s law of heat conduction, a second order differential equation is formed mathematically. This homogeneous linear differential equation predicts temperature distribution and heat flow rate in the dissimilar studs joined by friction stud welding process. Keywords: Friction stud welding, aluminium, mild steel, temperature distribution, heat fluxCite this Article Rajesh Jesudoss Hynes N, Tharmaraj R. One Dimensional Thermal Model for Heat Flow in Friction Stud Welding. Journal of Thermal Engineering and Applications. 2015; 2(2): 22–27p.
