Abstract
Numerical and physical modeling techniques are used to predict process behavior in friction stir welding (FSW) high strength aluminum alloys. The numerical approach uses a non-linear finite element method to characterize thermal and deformation behavior along the welded structure during FSW. Coupled temperature-displacement analysis is applied in order to determine temperature, displacement, and mechanical responses simultaneously. The physical modeling approach uses the response surface methodology (RSM) to evaluate the effects of the process controlling parameters on the properties of the welded joints. The results obtained, offer insights into the effects of the major process parameters in establishing successful FSW joints that satisfy further processing requirements and product service conditions.
Highlights
Friction stir welding (FSW) is a solid state welding process where localized deformation at the joint interface establishes the bond between the base metals Figure 1
FSW cycle consists of four stages: plunge stage;dwell stage; welding stage; and pulling tool out stage
They include tool rotational speed, travel speed of the tool, plunge force, plunge depth, and tool design [2,3,4,5,6,7,8,9,10,11,12,13]. These parameters affect the thermo-mechanical and metallurgical changes established during FSW which in turn are related to the evolved properties, microstructure, and process-induced damage in the course of the welding process
Summary
Friction stir welding (FSW) is a solid state welding process where localized deformation at the joint interface establishes the bond between the base metals Figure 1. The central difference integration rule is used to update the Finite element method velocities and displacements: Friction stir welding processes are inherently nonlinear because of the large strains, high temperature, and plastic behavior of the material in the welding zone. Mesh will follow the generation by both friction and plastic deformation are modeled rather than adding heat flux to the tool. The developed model deals with characterization of the responses of the material to the mechanical and thermal loading environment generated by friction stir welding. This model provides guidance for selecting the appropriate process conditions that result in desirable properties of the joint
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