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Modeling of AA5083 Material-Microstructure Evolution During Butt Friction-Stir Welding

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Abstract

A concise yet a fairly comprehensive overview of the friction stir welding (FSW) process is provided. This is followed by a computational investigation in which FSW behavior of a prototypical solution-strengthened and strain-hardened aluminum alloy, AA5083-H131, is modeled using a fully coupled thermo-mechanical finite-element procedure developed in our prior study. Particular attention is given to proper modeling of the welding work-piece material behavior during the FSW process. Specifically, competition and interactions between plastic-deformation and dynamic-recrystallization processes are considered to properly account for the material-microstructure evolution in the weld nugget zone. The results showed that with proper modeling of the material behavior under high-temperature/severe-plastic-deformation conditions, significantly improved agreement can be attained between the computed and measured post-FSW residual-stress and material-strength distribution results.

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Acknowledgments

This research article is based on project with financial support under the U.S. Army/Clemson University Cooperative Agreements, W911NF-04-2-0024 and W911NF-06-2-0042.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Clemson University, 241 Engineering Innovation Building, Clemson, SC, 29634-0921, USA

    M. Grujicic, G. Arakere, H. V. Yalavarthy & T. He

  2. Army Research Laboratory – Survivability Materials Branch, Aberdeen Proving Ground, MD, 21005-5069, USA

    C.-F. Yen & B. A. Cheeseman

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  1. M. Grujicic
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  2. G. Arakere
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  3. H. V. Yalavarthy
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  4. T. He
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  6. B. A. Cheeseman
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Correspondence to M. Grujicic.

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Grujicic, M., Arakere, G., Yalavarthy, H.V. et al. Modeling of AA5083 Material-Microstructure Evolution During Butt Friction-Stir Welding. J. of Materi Eng and Perform 19, 672–684 (2010). https://doi.org/10.1007/s11665-009-9536-1

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