Finite Element Simulation of Temperature and Strain Distribution in Al2024 Aluminum Alloy by Friction Stir Welding

Friction stir welding (FSW) is a solid state joining process and is handy for welding aluminum alloys. Numerical simulation of FSW is highly complex due to non-linear contact interactions between tool and work piece and interdependency of displacement and temperature. In the present paper a three dimensional finite element model is proposed to study the thermal history, strain distribution and thermo-mechanical process in butt welding of Aluminum alloy 2024 using DEFORM-3D software. Effect of tool rotational speed on plastic strain is studied and insight is given on asymmetric nature of friction stir welding process. Lagrangian incremental technique is used to model FSW process and sticking condition is defined between tool and work piece.