TWI

A 3D computational fluid dynamics model was developed to conduct numerical simulations of heat generation, material flow and temperature profiles during reverse dual-rotation friction stir welding, a process variant in which the tool pin and the assisted shoulder rotate oppositely and independently. The total heat generation rate at the tool-workpiece contact interface was calculated by taking into account both frictional heat and plastic deformation heat. Calculations were undertaken for welding of 2024 aluminium alloys. The process parameters varied were welding speed (50-200 mm/min) and rotational speed of assisted shoulder and pin (600-1200 rpm). Issues discussed include the occurrence of reverse material flows promoting temperature profile uniformity at advancing and retreating sides and the influence of rotational speed on the shape and size of the thermomechanically affected zone.

10th International Symposium, 20-22 May 2014, Poster Session, Paper 08