Abstract
An innovative methodology for the semi-analytical calculation of the total heat generated during the friction stir welding (FSW) process is proposed. The methodology includes a simple and straightforward procedure for the determination of the heat produced due to the material stirring, combines the advantages of the conventional moving heat approach with those of alternative modelling approaches, (i.e. computational fluid dynamics or arbitrary Lagrangian Eulerian), while, simultaneously, overcomes some of their main limitations. Moreover, the predicted FSW heat energy is introduced in a global three-dimensional finite element thermal model, which predicts the spatial temperature history developing in the welded parts during the process. The overall methodology is validated through experimental temperature measurements. Finally, the global thermal model results are introduced in a thermomechanical model, from which the residual stress and distortion fields are predicted. The proposed methodology can be easily modified and used in FSW applications of variable welded plate geometry, FSW tool type, joint type and process parameters.
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