Numerical Simulation of the Friction Stir Spot Welding Process

Friction Stir Spot Welding (FSSW), originally developed by GKSS (Germany), has a strong potential to find applications in the automotive and aerospace industries. At the present time, research efforts are taking place to gain a better understanding of the process, to explore different tool configurations, and to optimize the set of process parameters. In this regard, having reliable numerical models capable to simulate FSSW can be useful to reduce the number of physical experiments required in those studies. In this paper, a simplified isothermal three-dimensional Finite Element model of the initial plunge phase of the FSSW process is presented. The model, based on a solid mechanics approach, was developed using the commercial software ABAQUS/Explicit. The results of the simulations are compared against experimental information corresponding to similar tool geometry, sequence of operations, and process parameters.