Thermo-Mechanical Analysis of AA6061-T6 Plates in Friction Stir Welding at Varying Tool Speeds Using ANSYS

Abstract

Natural fibers derived from renewable sources have gained attention as sustainable reinforcing agents for composite material production. This study examines how varying the fiber volume ratio influences the mechanical and physical properties of natural fiber-reinforced composites, with fiber length and orientation kept constant. Composite specimens were fabricated using hemp, coconut, and jute fibers as reinforcements within a phenol-formaldehyde matrix. Four different fiber volume ratios—30% (S1), 40% (S2), 50% (S3), and 60% (S4)—were employed, while maintaining a consistent fiber length of 12 mm and a uniform sample thickness of 5 mm. In all samples, the fibers were randomly distributed.

The results demonstrated that fiber volume ratio significantly affects composite properties. The composite with 40% fiber content showed the highest density and the lowest water absorption in both 2-hour and 24-hour tests, along with the lowest moisture content. Conversely, the sample with 60% fiber content exhibited the greatest water absorption and moisture uptake. Dimensional stability analysis revealed that the 30% fiber content composite underwent the least expansion in length, width, and thickness, while the 60% fiber content composite displayed the greatest expansion. Mechanical testing showed that the highest modulus of elasticity was achieved at 50% fiber content, whereas the highest modulus of rupture was observed at 60%.

These findings underscore the importance of optimizing fiber volume ratio to enhance the physical and mechanical behavior of natural fiber composites. The study concludes that adjusting fiber content is key to improving performance, supporting the broader use of natural fiber composites as eco-friendly alternatives to conventional materials.

Cite as:

Pramod Kumar, & Tanuj Kumar Gupta. (2025). Thermo-Mechanical Analysis of AA6061-T6 Plates in Friction Stir Welding at Varying Tool Speeds Using ANSYS. Research and Reviews: Journal of Thermal Engineering, 7(2), 26–42. https://doi.org/10.5281/zenodo.15762616