Computational investigations on reliable finite element-based thermomechanical-coupled simulations of friction stir welding

Abstract

The finite element method was used in the current work to study the selection of the constitutive models, the selection of the frictional coefficients, the selection of the contact models and the selection of the physical parameters. Numerical results show that the shape of the shoulder can affect the material flows obviously and a total of about 54.3% energy can be transformed into heat in friction stir welding/friction stir processing (FSW/FSP). When the physical parameters are further considered to be functions of temperature, the predicted temperature is lower than the one in which the physical parameters are constant. When strainhardening effect is considered, the equivalent plastic strain is decreased and the corresponding energy dissipated by plastic deformation is decreased. The effect of the frictional coefficient on the prediction of the temperature field in FSW/FSP is small when the selection of the frictional coefficient is located in a reasonable small extent. The computational costs in the simulation of FSW/FSP are not only affected by the mesh sizes and wave speed but also affected by the mesh distortions. So, mesh distortions should be considered to be minimized in the numerical modeling of FSW/FSP to reduce the computational costs.

Research on Friction Stir Spot Welding Brazing Process and Properties of Dissimilar Metals DP590 and 6061

“…e geometric model of steel DP590 and aluminium alloy 6061 adopting the same joint form, size, and test parameters was established (Figure 8) [31,32]. e heat source model is shown in Figure 9 [33][34][35][36].…”

A Modified Analytical Heat Source Model for Numerical Simulation of Temperature Field in Friction Stir Welding

“…Moreover, only limited temperature data can be obtained via experimental measurement [6]. As a contrast, the numerical models can be very efficient and convenient to give global and detailed thermal information [7].…”

A Multi Scale Strategy for Simulation of Microstructural Evolutions in Friction Stir Welding of Duplex Titanium Alloy

“…The welding temperature in FSW is lower than the melting point (T m ) but higher than the temperature for recrystallization [26,27]. The heat in FSW is generated by two parts: the frictional and the plastic dissipations [28][29][30]. The temperature variations in FSW process have been widely studied in different models.…”