Material flow during friction stir welding: a thermo-mechanically fully coupled CFD study
- Chen G.Q. ,
- Feng Z.L. ,
- Zhu Y.C. ,
- et al
- Chen G.Q. ,
- Feng Z.L. ,
- Zhu Y.C. and
- Shi Q.Y.
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Based on a friction model incorporating the dynamic coupling between friction and material flow in heat transfer and fluid flow models, a computational fluid dynamics (CFD) methodology was employed to study material flow during friction stir welding and 3D distributions of temperature, material velocity, strain rate and strain were analysed via numerical simulation. Friction stir welding experiments were conducted to fabricate butt joints on AA 2024-T4 aluminium alloy sheets (thickness 3 mm) at a rotational rate of 1600 rpm and a travel speed of 20 mm/min. Thermocouples were used to measure workpiece temperature distributions during welding and macrostructure was observed by optical microscopy. Simulation models based on the CFD package ANSYS Fluent were developed to establish coupled multi-physics models and to take into account heat generation associated with plastic deformation. The distribution of transient and history-dependent variables between advancing and retreating sides is discussed.
10th International Symposium, 20-22 May 2014, Session 9B: Modelling II, Paper 04
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