Thermal-Structural Coupled Finite Element Analysis Of Heterogenous Metals In Friction Stir Welding Process

Researching on temperature field and stress-strain field in friction stir welding(FSW) exercise significant importance for analysis on heat transfer and hot recycle of the welding process, the form, flow, and distributing of the high temperature plastic cohesive metal in joint, welding metallurgy, stress-strain elastic-plastic dynamic behaviour and on the reliability and security of the welded structure. At present, the studies of FSW are focused on welding procedure, welding material, microstructure, friction stir mechanics, welding tools and machine etc. whereas dissertations about temperature distribution and stress-strain variation during FSW are not many.According to the physical dimension of the tool, 3D finite element heat-transfer model of FSW was made on the base of theoretical analysis of heat-transfer in this paper. With the finite element analysis software ANSYS and limited measured temperature data, red copper and brass FSW process thermal-structural coupled analysis was done. The results show that the heat source of 3mm thick T2 and H62 sheetmetal FSW is the line heat source. The analogy model can be further simplified as 2D planar model. The temperature distribution around the tool reached steady state in the intermediate stage of the welding. The variation tendency of equivalent stress and equivalent strain conformed with that of the temperature. On thickness direction, variations of stress and strain in different positions are consistent.