Transient Numerical Simulation the Friction Stir Welding Process of Aa 2017 Alloys, Contact Parameter Effects on Thermal History and Material Flow

Abstract

The present work is a 3D transient numerical simulation of material flow and heat transfer during the FSW process. The equations of energy, conservation of mass and momentum were solved in the Eulerian coordinate, in which the spatially variable thermo-physical properties and the non-Newtonian viscosity for the flow of material was calculated taking into account the deformation velocity, the temperature and the properties of the material depending on the temperature. In the purpose of calibrating the proposed model, the effects of contact conditions at the tool / work-piece interface such as the friction coefficient and the slip coefficient on thermal cycles, distribution and the evolution of the maximum value of the temperature have been studied. However, the results obtained show a significant asymmetry of the temperature and mass distribution. Convective heat transport was an important heat transfer mechanism near the tool surface. Furthermore, the numerically simulated temperature value, cooling rates and the length of the thermo-mechanically and thermally affected zone increase with increasing slip coefficient.

Hybrid multi-response optimization and analysis of UFSW process using entropy measurement: effect of tool deviation on mechanical properties of an optimum joint

“…But they have dealt with the number of differential equations and a set of formulas. As a result, obtaining results consume enormous time and require resources [16][17][18]. Actually, the welding processes have many responses related to each other, where to avoid the interaction effect between responses and obtain a real optimal point; all weld joint responses must be treated as one response [19].…”