<p>Physics behind the material flow during Friction Stir Welding (FSW) is an important factor that influences the joint quality. Using the numerical method can be a promising avenue to avoid high-cost post-production inspection, which is intended for mass production. In this study, a numerical framework is proposed for aluminum alloys to simulate material flow and predict different types of the defect, including cavity, tunnel, groove, and flash formation. Comparison of simulation results, including axial force, shape of plasticized nugget zone, and types, size, and location of defects against those from experimental tests showed good agreement. Although different aluminum alloys have different flowability at high temperatures, the model was capable of predicting two and three-dimensional space presentations of defects for aluminum alloys. Tunnel and groove defects were formed when either probe or probe and shoulder fail to forge material into the advancing side, respectively. Material flow at the shoulder-workpiece interface was highlighted to explain the flash formation. Flash was formed where the shoulder was not capable of confining the shoulder-driven material, and a part of the plasticized material flows upward.</p>

Predictive Modeling of Defect Formation in Friction Stir Welding

Paper Proceedings: https://asmedigitalcollection.asme.org/MSEC/MSEC2021/volume/85062

2021 International Manufacturing Science and Engineering Conference (MSEC2021)

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