Abstract
Chipping phenomena during the friction element welding (FEW) process is investigated using finite element modeling. Intensive chipping is observed in a cast aluminum alloy when it is welded to a steel alloy. A Coupled Eulerian-Lagrangian scheme is used to investigate the underlying mechanisms enabling chipping. It is found that chipping is severe when the friction element initially contacts the workpiece and tends to reduce as the former progresses into the latter. Chipping decreases with the increase of rotational speed and the decrease of linear feed rate. Chipping can be minimized by using high rotational speeds coupled with low feed rates.
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