Thermomechanical Modeling of a Friction Stir Welding Process

This work presents a numerical model of a friction stir welding, FSW, process. FSW is a solid-state welding technology. Unlike in conventional fusion welding processes, FSW doesn't melt a material. Thus, it is particularly suited for joining components made of aluminum alloys that are classified as poorly weldable or nonweldable. There are ongoing intensive efforts to develop numerical models of FSW process. However, most of the work is focused on describing the relationship between process parameters and the quality of a weld. Such models utilize computational fluid mechanics to describe the interaction between an FSW tool and a joined material. This work uses computational solid mechanics to describe the relationship between heat input and deformations occurring in welded components. The comparison of the calculated results and the actual FSW joint is presented.