Heat transfer and material flow modelling of friction stir welding
Friction stir welding is a solid state joining process which avoids common fusion welding defects such as liquation cracking, porosity, loss of alloying elements etc. Numerical models have been developed in past for various fusion welding processes. A three dimensional heat transfer and visco-plastic material flow model is developed to simulate friction stir welding of various alloys. The developed model can estimate temperature and velocity distribution along with torque, force and stresses on the tool. The computed values are validated using experimental results and are used to explain some of the experimental phenomena. This numerical model is then used to compute forces and stress on the tool. The maximum stress is computed for few cases reported in literature. It is shown that the safety factor calculations based on numerical model findings can explain the tool failure during FSW. The model is also developed for calculation of tool wear and tool pin profile during FSW.
Prof. A. Arora
Department of Materials Science & Engineering
Indian Institute of Technology Gandhinagar
Palaj, Gandhinagar - 382355, Gujarat
India
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