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Journal of Manufacturing Science and Engineering | Volume 132 | Issue 1 | Technical Brief
Technical Briefs

Simulation of a Refill Friction Stir Spot Welding Process Using a Fully Coupled Thermo-Mechanical FEM Model

[+] Author and Article Information
Karim H. Muci-Küchler1

Department of Mechanical Engineering, South Dakota School of Mines and Technology, 501 East Saint Joseph Street, Rapid City, SD 57701-3995Karim.Muci@sdsmt.edu

Sindhura Kalagara

Department of Mechanical Engineering, South Dakota School of Mines and Technology, 501 East Saint Joseph Street, Rapid City, SD 57701-3995

William J. Arbegast

Advanced Materials Processing and Joining Laboratory, South Dakota School of Mines and Technology, 501 East Saint Joseph Street, Rapid City, SD 57701-3995

1

Corresponding author.

J. Manuf. Sci. Eng 132(1), 014503 (Jan 25, 2010) (5 pages) doi:10.1115/1.4000881 History: Received December 17, 2008; Revised December 16, 2009; Published January 25, 2010; Online January 25, 2010
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Citing Articles

Friction stir spot welding (FSSW) is a solid state joining technology that has the potential to be a replacement for processes like resistance spot welding and rivet technology in certain applications. To optimize the process parameters and to develop FSSW tools, it is important to understand the physics of this complex process that involves frictional contact, high temperature gradients, and large deformations. This paper presents a fully coupled thermo-mechanical finite element model (FEM) model of the plunge phase of a modified refill FSSW. The model was developed in Abaqus/Explicit and the simulation results included the temperature, deformation, stress, and strain distributions in the plates being joined. An experimental study was also conducted to validate the temperatures predicted by the model. The simulation results were in good agreement with the temperatures measured in the experiment. Also, the model was able to predict in a reasonable fashion the stresses and plastic strains in the plates.
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References

1
Thomas, W. M., Nicholas, E. D., Needham, J. C., Murch, M. G., Michael, G., Templesmith, P., and Dawes, C. J., 1995, “Friction Stir Welding,” G. B. Patent No. 9125978.8 and U.S. Patent No. 5460317.
2
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Arbegast, W. J., 2006, “Friction Stir Welding After a Decade of Development,” Weld. J. (Miami, FL, U.S.), 85 , pp. 28–35.
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Iwashita, T., 2003, “Method and Apparatus for Joining,” U.S. Patent No. 6601751 B2.
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Okamoto, K., Hunt, F., and Hirano, S., 2005, “Development of Friction Stir Welding Technique and Machine for Sheet Metal Assembly,” SAE Paper No. 2005-01-1254.
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Badarinarayan, H., Hunt, F., and Okamoto, K., 2007, "Friction Stir Welding and Processing", Novelty, OH, pp. 235–272.
8
Buck, G. A., and Langerman, M., 2004, “Non-Dimensional Characterization of the Friction Stir/Spot Welding Process Using a Simple Couette Flow Model Part I: Constant Property Bingham Plastic Solution,” AIP Conf. Proc., 712 , pp. 1283–1288.  [CrossRef]
9
Gerlich, A., Su, P., Bendzsak, G. J., and North, T. H., 2005, “Numerical Modeling of FSW Spot Welding: Preliminary Results,” "Friction Stir Welding and Processing III", K.V.Jata, M.W.Mahoney, R.S.Mishra, and T.J.Lienert, eds., The Minerals, Metals and Materials Society, Warrendale, PA, pp. 221–224.
10
Su, P., Gerlich, A., North, T. H., and Bendzsak, G. J., 2007, “Intermixing in Dissimilar Friction Stir Spot Welds,” Metall. Mater. Trans. A, 38 , pp. 584–595.  [CrossRef]
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Awang, M., Mucino, V. H., Feng, Z., and David, S. A., 2005, “Thermo-Mechanical Modeling of Friction Stir Spot Welding Process: Use of an Explicit Adaptive Meshing Scheme,” SAE Paper No. 2005-01-1251.
12
Kakarla, S. S. T., Muci-Küchler, K. H., Arbegast, W. J., and Allen, C. D., 2005, “Three-Dimensional Finite Element Model of the Friction Stir Spot Welding Process,” "Friction Stir Welding and Processing III", K.V.Jata, M.W.Mahoney, R.S.Mishra, and T.J.Lienert, eds., The Minerals, Metals and Materials Society, Warrendale, PA, pp. 213–220.
13
Muci-Küchler, K. H., Kakarla, S. S. T., Arbegast, W. J., and Allen, C. D., 2005, “Numerical Simulation of the Friction Stir Spot Welding Process,” SAE Paper No. 2005-01-1260.
14
Itapu, S. K., and Muci-Küchler, K. H., 2006, “Visualization of Material Flow in the Refill Friction Stir Spot Welding Process,” SAE Paper No. 2006-01-1206.
15
Kalagara, S., and Muci-Küchler, K. H., 2007, “Numerical Simulation of a Refill Friction Stir Spot Welding Process,” "Friction Stir Welding and Processing IV", R.S.Mishra, M.W.Mahoney, T.J.Lienert, and K.V.Jata, eds., The Minerals, Metals and Materials Society, Warrendale, PA, pp. 369–378.
16
Badarinarayan, H., Hunt, F., Okamato, K., and Hirasawa, S., 2007, “Study of Plunge Motion During Friction Stir Spot Welding—Temperature and Flow Pattern,” "Friction Stir Welding and Processing IV", R.S.Mishra, M.W.Mahoney, T.J.Lienert, and K.V.Jata, eds., The Minerals, Metals and Materials Society, Warrendale, PA, pp. 311–322.
17
2008, "Abaqus Version 6.8 User Manuals", DDS Simulia, Providence, RI.
18
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21
Kakarla, S. S. T., 2005, “Simulation of the Initial Plunging Phase of the Friction Stir Spot Welding Process Using FEM,” MS thesis, South Dakota School of Mines and Technology, Rapid City, SD.
22
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24
Gerlich, A., Su, P., North, T. H., and Bendzsak, G. J., 2005, “Friction Stir Spot Welding of Aluminum and Magnesium Alloys,” Mater. Forum, 29 , pp. 290–294.
25
Xu, S., and Deng, X., 2003, “Two and Three-Dimensional Finite Element Models for the Friction Stir Welding Process,” "Proceedings of the Fourth International Symposium on Friction Stir Welding", Park City, UT.

Figures

Grahic Jump Location
+Main phases of the modified refill FSSW process
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Main phases of the modified refill FSSW process
Figure 1

Main phases of the modified refill FSSW process

Grahic Jump Location
+Parts included in the FEM model
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Parts included in the FEM model
Figure 2

Parts included in the FEM model

Grahic Jump Location
+Comparison of nodal temperatures at thermocouples T1 and T7
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Comparison of nodal temperatures at thermocouples T1 and T7
Figure 3

Comparison of nodal temperatures at thermocouples T1 and T7

Grahic Jump Location
+Comparison of predicted and experimental values for the tool plunge force
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Comparison of predicted and experimental values for the tool plunge force
Figure 4

Comparison of predicted and experimental values for the tool plunge force

Grahic Jump Location
+Comparison of predicted and experimental values for the tool torque
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Comparison of predicted and experimental values for the tool torque
Figure 5

Comparison of predicted and experimental values for the tool torque

Grahic Jump Location
+Temperature, von Mises stress and equivalent plastic strain contour plots at full plunge
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Temperature, von Mises stress and equivalent plastic strain contour plots at full plunge
Figure 6

Temperature, von Mises stress and equivalent plastic strain contour plots at full plunge

Grahic Jump Location
+Photomacrograph of a cross section at the center of a joint after the initial plunge phase
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Photomacrograph of a cross section at the center of a joint after the initial plunge phase
Figure 7

Photomacrograph of a cross section at the center of a joint after the initial plunge phase

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