Journal
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE
Volume 235, Issue 19, Pages 4194-4203Publisher
SAGE PUBLICATIONS LTD
DOI: 10.1177/0954406220962540
Keywords
Computational solid mechanics; friction stir welding; material flow modeling; design of tools; light alloys; magnesium alloys
Categories
Funding
- Brazilian Nanotechnology National Laboratory (LNNano) of the Brazilian Center for Research in Energy and Materials (CNPEM)
- Villares Metals
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A computational solid mechanic's model capable of simulating material flow and defect formation was presented, revealing that threads increase material velocity and strain rate, promoting better material flow and avoiding filling defects.
In the friction stir welding process, the tool role in the material flow and its thermomechanical behavior is still not entirely understood. Several modeling approaches attempted to explain the material and tool relationship, but to this date, insufficient results were provided in this matter. Regarding this issue and the urgent need for trustful friction stir welding models, a computational solid mechanic's model capable of simulating material flow and defect formation is presented. This model uses an Arbitrary Lagrangian-Eulerian code comparing a threaded and unthread pin profile. The model was able to reproduce the tool's torque, temperatures, and material flow along the entire process, including the underreported downward flow effect promoted by threaded pin's. A point tracking analysis revealed that threads increase the material velocity and strain rate to almost 30% compared to unthreaded conditions, promoting a temperature increment during the process, which improved the material flow and avoided filling defects. The presented results showed the model's capability to reproduce the defects observed in real welded joints, material thermomechanical characteristics and high sensitivity to welding parameters and tool geometries. Nevertheless, the outcomes of this work contribute to essential guidelines for future friction stir welding modeling and development, tool design, and defect prediction.
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