A computational model for the numerical simulation of FSW processes

Abstract

In this paper a computational model for the numerical simulation of Friction Stir Welding (FSW) processes is presented. FSW is a new method of welding in solid state in which a shouldered tool with a profile probe is rotated and slowly plunged into the joint line between two pieces of sheet or plate material which are butted together. Once the probe has been completely inserted, it is moved with a small tilt angle in the welding direction. Here a quasi-static, thermal transient, mixed multiscale stabilized Eulerian formulation is used. Norton-Hoff and Sheppard-Wright rigid thermoviscoplastic material models have been considered. A staggered solution algorithm is defined such that for any time step, the mechanical problem is solved at constant temperature and then the thermal problem is solved keeping constant the mechanical variables. A pressure multiscale stabilized mixed linear velocity/linear pressure finite element interpolation formulation is used to solve the mechanical problem and a convection multiscale stabilized linear temperature interpolation formulation is used to solve the thermal problem. The model has been implemented into the in-house developed FE code COMET. Results obtained in the simulation of FSW process are compared to other numerical results or experimental results, when available.