Multi-physics Models for Friction Stir Welding Simulation

Friction stir welding (FSW) is a solid-state welding technology for joining a range of metals and alloys. The FSW joining process involves several coupled non-linear phenomena including; frictional heating, large plastic deformation, material transportation and dissipative heating. Numerical simulation of the process may include some or all of these physical processes, depending on the objective of the analysis. This paper gives an overview of two continuum solid mechanics FSW simulation models of differing complexity. The first model is a simplified ANSYS thermo-mechanical finite element model with an externally applied heat source simulating frictional and dissipative heating. The model can be used to quickly evaluate temperature, stress and deformation of the welded plate for a specified heat input. The second model is an ABAQUS/EXPLICIT Arbitrary Lagrangian-Eulerian (ALE) model of the complete FSW process: plunge, dwell, travel and withdraw. The model simulates coupled frictional heating, plastic dissipation, transient heat transfer and solid-state material flow. The results obtained for transient temperature distribution, material flow, residual stress and strain, etc. are found to be consistent with experimental observations.