Computational resources are such that process engineers might consider the use of computer models during the development of the manufacturing process of complex fabrications. However, it might not be possible for such an engineer to obtain reliable materials data, because manufacturing processes tend to require property data for a set of loading conditions that is so extensive that such data is only available for a small number of materials. The current paper discusses the development of a Friction Stir Weld (FSW) modelling method using only generally available material data for a wide range of materials. The method assumes that accuracy depends upon the conditions close to the FSW tool plus some straightforward mechanics and thermodynamics remote from the tool. The material model was implemented in STAR-CCM +, a commercially available computational fluid dynamics code, and the results from the model have been compared with measurements made on a test weld.
- Friction stir welding