Comparison of Two Numerical Models for Friction Stir Welding

In this paper, two numerical models of friction stir welding of two aluminum plates are considered. The coupled mechanical-temperature problem is solved with explicit integration over the time. The two models are based on the finite elements method (FEM) and have different complexity and number of participating parameters. The aim of the development is to highlight the weaknesses and strengths of the models of different complexity. The first model is simpler and it is based on the free penetration of the tool into the parts. The second model is based on the arbitrary Lagrange-Euler method and take into account the instrument penetration that allows to take into account the movement of the material in the process area. Convective and radiative heat transfers are accounted in the two models. The results for the temperature, stress and strain in the welded joint are studied and compared. The calculation time is given for each model. A parametric analysis was performed for the influence of the rotational speed of the pin, welding velocity and the pressing force. The influence of the temperature dependent physical properties of the welded plates is determined and compared for both finite element models. © 2022 Trans Tech Publications Ltd, Switzerland.