Numerical Simulation of Heat Generation, Heat Transfer and Material Flow in Friction Stir Welding

doi:10.11900/0412.1961.2017.00294

Acta Metall Sin

2018, Vol. 54

Issue (2): 265-277 DOI: 10.11900/0412.1961.2017.00294

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Numerical Simulation of Heat Generation, Heat Transfer and Material Flow in Friction Stir Welding

Chuansong WU(

), Hao SU, Lei SHI

Key Laboratory for Liquid-Solid Structure Evolution and Materials Processing (Ministry of Education), Shandong University, Jinan 250061, China

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Chuansong WU, Hao SU, Lei SHI. Numerical Simulation of Heat Generation, Heat Transfer and Material Flow in Friction Stir Welding. Acta Metall Sin, 2018, 54(2): 265-277.

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Abstract

The heat generation, heat transfer and plasticized material flow in friction stir welding determine directly the microstructure evolution and mechanical properties of weld joints. Numerical simulation of these thermo-physical phenomena is of great significance for getting a deep insight into the underlying mechanisms and optimizing the process parameters of friction stir welding. This article reviews the progress status in numerical simulation of heat generation, heat transfer and plasticized material flow behaviors in friction stir welding, and outlines the unsolved problems. The research work targeting these issues, which has been conducted by the authors' group, is introduced. According to the stress characteristics at the tool-workpiece interface, the expressions of sticking rate and friction coefficient are developed, and this measurement-calculation method lays foundation for improving the accuracy of numerical analysis. Through synthetically considering the characteristics of complex-shaped tools, a three dimensional model of friction stir welding process is established. Three types of tools are taken into consideration, i.e., normal CT (conical-pin tool), ST (conical-pin with 4 flats tool) and TT (conical-pin with 3 flats tool). For the cases in application of these tools, the heat generation, temperature profile, and material flow velocity are analyzed quantitatively. A mathematical model for the whole friction stir welding process including plunge stage, dwell stage, welding stage, and cooling stage is established for numerical analysis of transient development in heat generation rate, temperature and material flow fields in each stages. Based on the status review, the trend in numerical simulation of frictions stir welding is outlooked, and the research focus for next step is proposed.

Key words: friction stir welding heat generation heat transfer material flow numerical simulation

Received: 17 July 2017

Fund: Supported by National Natural Science Foundation of China (No.51475272)

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https://www.ams.org.cn/EN/10.11900/0412.1961.2017.00294 OR https://www.ams.org.cn/EN/Y2018/V54/I2/265

Fig.1 The influence factors of heat generation in friction stir welding (FSW)

Fig.2 Heat generation distribution^[12] (AS—advancing side, RS—retreating side)(a) heat flux generated by interfacial friction(b) volumetric heat density generated by plastic deformation

Table 1 The calculated sticking coefficients and friction coefficients under different conditions

Fig.3 Schematic drawings of FSW process (a) and different stages in FSW (b) (v_p—plunge speed, v_w—welding speed)

Fig.4 Calculated heat generation versus time during the FSW process^[38]

Fig.5 Calculated temperature distributions at a transverse section during the plunge stage^[38]
(a) 4.5 s (b) 15.0 s (c) 24.9 s (d) 28.2 s

Fig.6 Calculated temperature distributions at a transverse cross-section during the dwell and welding stages^[38]
(a) 28.51 s (b) 30.0 s (c) 37.9 s (d) 45.0 s (e) 50.1 s (f) 60.0 s

Fig.7 The predicted streamlines near the tool during the welding stage at a plane 2 mm below the top surface of workpiece (75.0 s)^[38]

Fig.8 Cross-sections of various pin profiles?(a) cylindrical (b) triflat(c) triflute (d) trivex (e) square

Fig.9 Cross-sections of triflute pin at different time in one rotation cycle (t₀—a specific moment, t_p—rotation cycle)

Fig.10 Temperature evolution at two points of z=3 mm plane during tool rotating (TT, Case No.5)^[45]

Fig.11 Volumetric heat density distributions inside the shear layer (Case No.9)^[44](a) z=5.5 mm (b) z=2.5 mm

Fig.12 Plastic flow (left) and streamline (right) distributions at z=3 mm plane (Case No.7)(a) CT (b) ST (c) TT

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