Two-Dimensional Finite Element Simulation of Material Flow in the Friction Stir Welding Process

AbstractIn an effort to enhance safety for long time disposal of waste nuclear fuel, friction stir welding has been developed as one alternative to seal copper canisters. To avoid the formation of voids and cracks during the welding process, an understanding of the heat and material flow andthereby the evolution of the microstructure, is of great importance. Finite element modelling has been used to simulate the heat and material flow as well as thermal expansion during the friction stir welding process. A model involving heat transfer, material flow, and continuum mechanics has been developed. The steady state solutions have been compared with experimental temperature observations as well as analytical solutions, showing good agreement. Temperature distribution is affected by the welding speed. For a given reference pointperpendicular to the welding direction, a lower welding speed corresponds to a higher peak temperature. The plunging position of welding tool influences the temperature distribution and therefore the displacement distribution of the weldment.

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A modified friction model and its application in finite-element analysis of friction stir welding process

Journal of Manufacturing Processes ◽

10.1016/j.jmapro.2021.10.008 ◽

2021 ◽

Vol 72 ◽

pp. 29-47

Author(s):

Bahman Meyghani

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Friction Stir Welding ◽

Welding Process ◽

Friction Model ◽

Element Analysis ◽

Friction Stir ◽

Friction Stir Welding Process

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A Finite Element Model for the Prediction of Chip Formation and Surface Morphology in Friction Stir Welding Process

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4052526 ◽

2021 ◽

pp. 1-21

Author(s):

Debtanay Das ◽

Swarup Bag ◽

Sukhomay Pal ◽

M. Ruhul Amin

Keyword(s):

Finite Element ◽

Friction Stir Welding ◽

Surface Morphology ◽

Chip Formation ◽

Material Flow ◽

Welding Process ◽

Measured Temperature ◽

Material Loss ◽

Friction Stir ◽

Mass Scaling

Abstract Friction stir welding (FSW) is widely recognized green manufacturing process capable of producing good quality welded joints at temperature lower than the melting point. However, most of the works is focused on to the establishment of the process parameters for a defect-free joint. There is a lack to understand the formation of defects from physical basis and visualization of the same, which is otherwise difficult to predict by means of simple experiments. The conventional models do not predict chip formation and surface morphology by accounting the material loss during the process. Hence, a 3D finite element based thermo-mechanical model is developed following Coupled Eulerian-Lagrangian (CEL) approach to understand surface morphology by triggering material flow associated with tool-material interaction. In the present quasi-static analysis, the mass scaling factor is explored to make the model computationally feasible by varying the FSW parameter of plunge depth. The simulated results are validated with experimentally measured temperature and surface morphology. In CEL approach, the material flow out of the workpiece enables the visualization of the chip formation, whereas small deformation predict the surface quality of the joint.

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