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

Karim H. Muci-Küchler; Sindhura Kalagara; William J. Arbegast

doi:10.1115/1.4000881

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

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

Karim H. Muci-Küchler, Sindhura Kalagara and William J. Arbegast

[+] 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

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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Abstract

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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Main phases of the modified refill FSSW process

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Figure 1

Main phases of the modified refill FSSW process

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Figure 2

Parts included in the FEM model

Comparison of nodal temperatures at thermocouples T1 and T7

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Figure 3

Comparison of nodal temperatures at thermocouples T1 and T7

Comparison of predicted and experimental values for the tool plunge force

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Figure 4

Comparison of predicted and experimental values for the tool plunge force

Comparison of predicted and experimental values for the tool torque

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Figure 5

Comparison of predicted and experimental values for the tool torque

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

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Figure 6

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

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

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Figure 7

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

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Muci-Küchler KH, Kalagara S, Arbegast WJ. Simulation of a Refill Friction Stir Spot Welding Process Using a Fully Coupled Thermo-Mechanical FEM Model. ASME. J. Manuf. Sci. Eng. 2010;132(1):014503-014503-5. doi:10.1115/1.4000881.

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

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