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Metals 2017, 7(7), 256; doi:10.3390/met7070256

A Finite Element Model to Simulate Defect Formation during Friction Stir Welding

State Key Laboratory of Robotics, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, China
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Received: 16 June 2017 / Revised: 27 June 2017 / Accepted: 28 June 2017 / Published: 7 July 2017
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Abstract

In this study, a 3D coupled thermo-mechanical finite element model is developed to predict and analyze the defect formation during friction stir welding based on coupled Eulerian Lagrangian method. The model is validated by comparing the estimated welding temperature, processed zone shape and void size with those obtained experimentally. The results compared indicate that the simulated temperature and the data measured are in good agreement with each other. In addition, the model can predict the plasticized zone shape and the presence of a void in the weld quite accurately. However, the void size is overestimated. The effects of welding parameters and tool pin profile are also analyzed. The results reveal that welding at low welding speed or high tool rotational speed could produce a smaller void. Moreover, compared to a smooth tool pin, a featured tool pin can enhance plastic flow in the weld and achieve defect-free weldment. The results are helpful for the optimization of the welding process and the design of welding tools. View Full-Text
Keywords: friction stir welding; Al6061-T6; material flow; welding detect; finite element simulation; coupled Eulerian Lagrangian friction stir welding; Al6061-T6; material flow; welding detect; finite element simulation; coupled Eulerian Lagrangian
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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Zhu, Z.; Wang, M.; Zhang, H.; Zhang, X.; Yu, T.; Wu, Z. A Finite Element Model to Simulate Defect Formation during Friction Stir Welding. Metals 2017, 7, 256.

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