Analysis on friction stir welding process of 7022 aluminum alloy

Abstract

The state of the simulation technology widely used in friction stir welding (FSW) studies requires greater and greater accuracy. An analysis is made of an FSW dynamic heat source model and related information. The model is combined with results from FSW experiments and the welding temperature field. A relationship is obtained for the friction coefficient between the tool and welding materials with temperature. By incorporating tool force measurements and analysis, a simulation model which is much more in line with actual FSW results is thus established. In the simulation process, the temperature of each part of the tool, the material model, fixture constraints, and the role of tool–material forces are analyzed and discussed in detail. In the new model, the different input heats on the advancing and retreating sides on the shoulder, the pin surround, and top of the pin are distinguished. The mechanical properties of the materials with change in temperature and the constitutive equations for the welding, before and after, are obtained. The contact relationship between the fixture and workpiece was built. In the welding process, the forces of the tool toward the welding material were applied. The 7022 aluminum alloy FSW process was simulated by the constructed simulation model. The temperature field, residual stress, and deformation in the simulations were in good agreement with the experiment results.