Numerical Simulation of Friction Stir Welding of Aluminium Plate

Abstract

Friction Stir Welding (FSW) is one of the most effective solid state joining processes and has numerous potential applications in many industries. The aim of this paper is to describe the thermal-fluid and mechanical simulation of FSW using the finite element method in program SYSWELD. The simulation of FSW process requires the modelling of the complex interaction between thermal, metallurgical and mechanical phenomena. Thermal-mechanical results from the numerical simulation using SYSWELD are here presented for aluminium alloy.

Comparing Numerical and Experimental Solutions of Friction Stir Welding of an Aluminium Plate

“…For the numerical solution of the thermal field we used SYSWeld, a software, with the FSW (Friction Stir Welding) module. The steps of the solution are described in , Jančo et al, 2019 For the simulation aluminium alloy AlMg4.5Mn0.7 was used with material properties presented in , which is the function of temperature. The blacking plate was made of steel, again, the material properties are described in in For the welding process we used the following properties: the friction coefficient was 0.238, the linear welding velocity was 1.67 mm/s, the tool rotation velocity was 41.89 rad.s -1 , the room temperature was 15 °C and the heat exchange coefficient for convection was 19 W/(m 2 .K).…”

“…6. The boundary conditions are described in detail in Jančo et al, 2019. Results of the thermo-fluid analysis is presented in Fig.…”

“…Friction stir welding (FSW) is a relatively new joining technology which was developed and patented in 1991 by The Welding Institute (TWI) in the United Kingdom (Chen and Kovacevic, 2003). The description of the principle of friction stir welding is described in previous papers of the authors , Jančo et al, 2019. This welding technique can be applied in the automobile, aerospace industries as well as other places of engineering (Frigaard et al, 2001, Feulvarch et al, 2007.…”