In this paper, we aim to investigate the heat generated during friction stir lap welding in polypropylene sheets. In this method, the generated heat significantly depends on the tool’s rotational and linear speed, geometry, and tilt angle. Heat analysis and measurement during welding are performed numerically to validate the experimental results. A 3-D symmetric Finite Element (FE) model was created to estimate the generated and distributed heat. As is shown, the heat is mainly generated around and underside the tool due to the high friction between the rotating tool and the workpiece. This paper provided a good intuition on the generated and distributed heat during the FSW process, which can be considered a reference to produce optimum and high-quality products with fewer tests. Therefore, in this paper, the effect of a number of parameters on the generated heat during the welding process is studied experimentally and statistically and simulated in three different levels. The obtained results demonstrated a significant relationship between the properties and process parameters using analysis of variance (ANOVA) and response surface method (RSM) (Box-Behnken). Moreover, the results revealed that the effect of parameter interactions could be evaluated using the proposed mathematical model by analyzing the presented plots. In addition, the results from the simulated model using finite element software and Altair’s HyperWorks confirmed the mathematical model estimations and the experimental results. The created model can successfully predict 92% of the welding joint temperature using the conditions and materials proposed in this paper. The results of the simulation analysis were validated and compared with the experimental tests, indicating a temperature difference of approximately 6%. The most effective parameter in heat generation is the rotational speed of the tool, which is responsible for up to 70% of the overall heat. Tool’s geometry (15%), traveling speed (11%), and tilt angle (4%) are the other parameters effective in generating heat in the process, in respective order.

在本文中，我们旨在研究在聚丙烯薄板的摩擦搅拌搭接焊接过程中产生的热量。在这种方法中，产生的热量很大程度上取决于工具的旋转速度和线速度，几何形状以及倾斜角度。对焊接过程中的热分析和测量进行了数值分析，以验证实验结果。创建了一个3-D对称有限元（FE）模型来估计所产生和分配的热量。如图所示，由于旋转工具和工件之间的高摩擦力，热量主要在工具周围和下方产生。本文对FSW过程中产生的热量和分布的热量提供了很好的直觉，可以认为是通过较少的测试即可生产出最佳，高质量产品的参考。因此，在本文中，实验和统计研究了许多参数对焊接过程中产生的热量的影响，并在三个不同级别上进行了模拟。使用方差分析（ANOVA）和响应面方法（RSM）（Box-Behnken），获得的结果证明了性能与工艺参数之间的显着关系。此外，结果表明，可以使用所提出的数学模型通过分析呈现的图来评估参数交互作用的效果。此外，使用有限元软件和Altair的HyperWorks从仿真模型获得的结果证实了数学模型的估计和实验结果。使用本文提出的条件和材料，创建的模型可以成功地预测92％的焊接接头温度。仿真分析的结果得到了验证，并与实验测试进行了比较，表明温差约为6％。热量产生中最有效的参数是工具的转速，该转速最多可占总热量的70％。工具的几何形状（15％），行进速度（11％）和倾斜角（4％）是在过程中有效产生热量的其他参数（按顺序）。