TWI

The ScanStir framework, comprising an experimental friction stir welding (FSW) set-up, numerical models based on open source finite element method software packages, and a high performance computer, was used to simulate the residual stress profile in a benchmark problem involving FSW of 2014 aluminium alloy sheets (thickness 4 mm). The simulation framework incorporated analytical heat source models, the thermal-pseudo-mechanical model, the pseudo-frictional-force model and an analytical expression for material flow around the tool. FSW experiments were conducted at a rotational speed of 1200 rpm and a welding speed of 200 mm/min. The numerical model was developed in the Calculix finite element package and results were obtained for residual stress and temperature profiles. ScanStir was employed to simulate wave propagation through weldments containing voids for laser ultrasound inspection.

10th International Symposium, 20-22 May 2014, Session 7A: Inspection, Paper 03