Investigating surface defect by tool-material interaction in friction stir welding using coupled Eulerian-Lagrangian approach

Abstract

Defect in welded joint can lead to significant loss of material and the quality of the joint. The intricate profile of the welded joint in FSW relies on appropriate process parameters with proper tool-material interaction. A finite element model using coupled Eulerian-Lagrangian approach craters the temperature distribution and material flow behaviour. These two characteristic parameters assist to predict the initiation, location, and dimension of the surface defect appeared due to interplay between FSW tool and substrate material. The critical process parameters predict the defective joint and alternatively direct to find the conditions for defect-free joints.