3D modeling of material flow in friction stir welding under different process parameters

Material flow in friction stir welding (FSW) under different process parameters is simulated by using the finite element technique based on the nonlinear continuum mechanics. Results indicate that the distribution of the equivalent plastic strain correlates well with the distribution of the microstructure zones in the weld. It seems that there is a quasi-linear relation between the change of the axial load on the shoulder and the variation of the equivalent plastic strain. The material flow can be accelerated with the increase of the translational velocity and the angular velocity of the pin. There exists a swirl on the advancing side and the material flow in the swirl on the advancing side becomes faster with the increase of the translational velocity. (c) 2006 Elsevier B.V. All rights reserved.