CFD numerical model development for Friction Stir Welding of aluminum alloys

L. BUGLIONI, L. TUFARO; H. G. SVOBODA

Rio de Janeiro

Congreso; XXXVI Ibero-Latin American Congress on Computational Methods in Engineering CILAMCE 2015; 2015

PUC-Rio

In the present work different Computational Fluid Dynamics (CFD) models forFriction Stir Welding (FSW) of aluminum alloys were developed and studied. Experimentalvalidation was done, for which, plates of AA5083 were butt-welded by FSW with four differentconditions, varying tool rotational and travel speed. From the welding process were measuredthermal cycles at different distances from the weld centerline in conjunction with axial forceand energy consumption. In addition, macrographs of transversal cuts the different zones forall welding conditions have been prepared. These measures were used to calibrate models andto compare them. Proposed models, with specific input parameters, were evaluated for thedifferent welding conditions experimentally done, and the numerical results were comparedwith measured variables of the process (thermal cycles, consumed power, axial force, stirredzone). Numerical input parameters used in each model (dissipation condition, heat generationmechanism, boundary conditions, etc.) were studied in order to predict its influence over modelresults and to find the better ones that enhance its prediction capacity. Models also have beencompared between them to achieve a representative model which fulfill best match withexperimental data.