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Computational analysis of thermo-mechanical characteristics in refill FSSW of thin AA7075-T6 sheets using smoothed-particle hydrodynamics

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Abstract

A 3D thermo-mechanical model was developed employing the smoothed-particle hydrodynamics (SPH) technique to simulate the refill friction stir spot welding (refill FSSW) process and its tool plunging variants. SPH is a Lagrangian particle-based approach that can directly trace field variables’ histories, handle large material deformations, and capture moving interfaces. These features of SPH make it appealing for the refill FSSW process, where the change of field variables is challenging to monitor experimentally. The numerical model of the shoulder-plunging variant (SP-refill FSSW) was validated by comparing results to experimental thermal data from the published literature. The temperatures correspond well with the experimental thermal data, and the model accurately predicted temperatures in the weld zone with an error of 0.52%. The thermal distribution, plastic strains, and material flow behaviours of the SP-refill FSSW and probe plunging variants (PP-refill FSSW) during the process are presented. The hook formation in connection with the material flow of the process is explained. The SPH numerical model can simulate refill FSSW, withstand severe deformations, and efficiently predict the field variables that help in a deeper understanding of the thermo-mechanical characteristics and joint formation in refill FSSW.

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Notes

  1. Note that the dimension of the shoulder, probe and clamping ring are varied depending on the variant.

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Acknowledgements

The authors acknowledge the funding they received from the Graduate Assistant Scheme at Universiti Teknologi PETRONAS and the help they received from Altair Engineering. Additionally, we appreciate the High-Performance Computing support for the simulations provided by the UTP-Altair Centre of Excellence for Applied Scientific Computing.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Universiti Teknologi PETRONAS, 32610, Seri Iskandar, Malaysia

    Venkata Somi Reddy Janga, Mokhtar Awang & Nabihah Sallih

  2. Altair Engineering Sdn Bhd, 50470, Kuala Lumpur, Malaysia

    Chan Ray Mun & Eng Ban Wee

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  1. Venkata Somi Reddy Janga
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Contributions

VSRJ designed the methodology, conducted simulations and numerical analysis, and drafted and revised the manuscript. MA and NS provided resources and supervised the study, with MA also contributing to the methodology and manuscript review. CRM and EBW assisted with numerical modelling and manuscript review.

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Correspondence to Mokhtar Awang.

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Janga, V.S.R., Awang, M., Sallih, N. et al. Computational analysis of thermo-mechanical characteristics in refill FSSW of thin AA7075-T6 sheets using smoothed-particle hydrodynamics. Comp. Part. Mech. (2023). https://doi.org/10.1007/s40571-023-00663-1

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