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<p>Using the Arbitrary-Lagrangian-Eulerian (ALE) framework, the current research has been primarily focused on studying the dynamic behavior of thermal-material flow-structural mechanics phenomena during friction stir welding (FSW) process at different tool rotational speeds (RS) of threaded conical tool-pin. The practical aspects such as shoulder penetration, tool tilt-angle, nonuniform heat generation, relative motion between the rigid tool and deforming workpiece material, and elastoplasticity with large plastic deformation strains were considered. As a result of the coupled phenomena model, temperature distribution and weld zones, plasticized material flow and mixing, shear stress-strain rates and material deformation were predicted. A close agreement was found between the predictions and experiments on the size of weld zones with a relative error less than 3.5%. Further, the predicted shear strain-rates on advancing side found to be higher by about 15% in contrast to retreating side, and it is attributed to higher material flow with mixing and hence higher material temperatures due to tool rotational motion. The measured average grain sizes at top, mid and bottom of the weld nugget zone (WNZ) center found to decrease with increasing tool’s RS, and it is attributed to more dynamic recrystallization due to increased shear train rates.</p>

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Arbitrary-Lagrangian-Eulerian Model Predictions and Experimental Investigations on Friction Stir Welding of Thick AA2219-T87 Plates

  • 期刊论文

  • 发表日期：

    2025年11月21日

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  • Ramana Murthy Bagadi,
  • Jeevan Jaidi,
  • G.M. Karthik,
  • Suresh D. Meshram

摘要

Using the Arbitrary-Lagrangian-Eulerian (ALE) framework, the current research has been primarily focused on studying the dynamic behavior of thermal-material flow-structural mechanics phenomena during friction stir welding (FSW) process at different tool rotational speeds (RS) of threaded conical tool-pin. The practical aspects such as shoulder penetration, tool tilt-angle, nonuniform heat generation, relative motion between the rigid tool and deforming workpiece material, and elastoplasticity with large plastic deformation strains were considered. As a result of the coupled phenomena model, temperature distribution and weld zones, plasticized material flow and mixing, shear stress-strain rates and material deformation were predicted. A close agreement was found between the predictions and experiments on the size of weld zones with a relative error less than 3.5%. Further, the predicted shear strain-rates on advancing side found to be higher by about 15% in contrast to retreating side, and it is attributed to higher material flow with mixing and hence higher material temperatures due to tool rotational motion. The measured average grain sizes at top, mid and bottom of the weld nugget zone (WNZ) center found to decrease with increasing tool’s RS, and it is attributed to more dynamic recrystallization due to increased shear train rates.