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A Fully Coupled Thermomechanical Model of Friction Stir Welding (FSW) and Numerical Studies on Process Parameters of Lightweight Aluminum Alloy Joints

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Acta Metallurgica Sinica (English Letters) Aims and scope

Abstract

This paper presents a new thermomechanical model of friction stir welding which is capable of simulating the three major steps of friction stir welding (FSW) process, i.e., plunge, dwell, and travel stages. A rate-dependent Johnson–Cook constitutive model is chosen to capture elasto-plastic work deformations during FSW. Two different weld schedules (i.e., plunge rate, rotational speed, and weld speed) are validated by comparing simulated temperature profiles with experimental results. Based on this model, the influences of various welding parameters on temperatures and energy generation during the welding process are investigated. Numerical results show that maximum temperature in FSW process increases with the decrease in plunge rate, and the frictional energy increases almost linearly with respect to time for different rotational speeds. Furthermore, low rotational speeds cause inadequate temperature distribution due to low frictional and plastic dissipation energy which eventually results in weld defects. When both the weld speed and rotational speed are increased, the contribution of plastic dissipation energy increases significantly and improved weld quality can be expected.

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Acknowledgements

The authors are grateful for the financial support provided by Louisiana Economic Development Assistantship (EDA) program. This work is also partially supported by NASA through the NASA-SLS Grant # NNM13AA02G. The authors would like to thank the National Center for Advanced Manufacturing (NCAM), NASA’s Michoud Assembly Facility at New Orleans-Louisiana, and NASA’s Marshall Space Flight Center for their help in providing the facility for the experimental program.

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Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, Louisiana State University, Baton Rouge, LA, 70803, USA

    Saad B. Aziz, Mohammad W. Dewan, Daniel J. Huggett, Muhammad A. Wahab & T. Warren Liao

  2. Department of Civil and Environmental Engineering, Louisiana State University, Baton Rouge, LA, 70803, USA

    Ayman M. Okeil

Authors
  1. Saad B. Aziz
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  2. Mohammad W. Dewan
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  3. Daniel J. Huggett
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  4. Muhammad A. Wahab
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  5. Ayman M. Okeil
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  6. T. Warren Liao
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Correspondence to Muhammad A. Wahab.

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Available online at http://link.springer.com/journal/40195

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Aziz, S.B., Dewan, M.W., Huggett, D.J. et al. A Fully Coupled Thermomechanical Model of Friction Stir Welding (FSW) and Numerical Studies on Process Parameters of Lightweight Aluminum Alloy Joints. Acta Metall. Sin. (Engl. Lett.) 31, 1–18 (2018). https://doi.org/10.1007/s40195-017-0658-4

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  • DOI: https://doi.org/10.1007/s40195-017-0658-4

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