Friction Stir Welding of Aluminum Plate: COMSOL Simulation
Friction Stir Welding of an Aluminum
Plate
COMSOL
Background
Manufacturers use a modern welding method called friction stir welding to join aluminum
plates
A rotating tool moves along the weld joint and softens aluminum by generating frictional
heat. The rotation then stirs the softened aluminum so that the two plates are joined
This method allows dissimilar materials and plastics to be welded together
The result is a pore-free weld joint without residual stresses due to shrinkage
Heat transfer between the rotating tool and the plate during welding is considered in this
model
Model Definition
A symmetry is introduced to
reduce the computational cost
Instead of modeling the tool as a
moving heat source, a moving
coordinate system fixed to the
tool axis is used
Two infinite element domains ,
before and after the welding
zone, are used to model an
infinitely long plate
Model geometry
Model Definition
Model geometry
The rotating tool is divided into
two parts: a pin with an inner
contact, and a shoulder with a
contact surface on the plate. The
shoulder itself is not represented
Model Definition
Heat fluxes from friction with the
rotating tool are taken into
account on both contact surfaces.
They account for the rotating
speed and the normal force
The heat fluxes from friction are
set to 0 if the temperature
exceeds the melting temperature
Surface-to-ambient radiation as
well as convection are considered
on the plate
Model boundary conditions
Model Definition
Model boundary conditions
The right side of the infinite plate,
which corresponds to the supply
side, is set to ambient
temperature
Results
In this configuration the maximum
temperature is 935 K which is
slightly higher than the melting
temperature of aluminum (T=933
K)
There is a thin film of aluminum
that melts at the very surface in
contact with the shoulder and the
pin
Cold material arrives on the
welding tool as the plate moves
Isothermal contours in the domain - In blue, the area where the
temperature exceeds 933 K
Results
Isothermal contours in the domain - In blue, the area where the
temperature exceeds 933 K
The high temperatures created by
the friction with the tool are then
transported
Manufacturers use friction stir welding to join aluminum plates efficiently. This modern method generates frictional heat to soften the aluminum, allowing dissimilar materials to be welded together. The model in COMSOL considers heat transfer and boundary conditions to simulate the welding process, resulting in a pore-free weld joint with minimal residual stresses. The symmetrical model reduces computational costs by simplifying the representation of the rotating tool. The results show temperature distributions and the melting behavior of aluminum during the welding process.
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Presentation Transcript
Friction Stir Welding of an Aluminum Plate COMSOL
Background Manufacturers use a modern welding method called friction stir welding to join aluminum plates A rotating tool moves along the weld joint and softens aluminum by generating frictional heat. The rotation then stirs the softened aluminum so that the two plates are joined This method allows dissimilar materials and plastics to be welded together The result is a pore-free weld joint without residual stresses due to shrinkage Heat transfer between the rotating tool and the plate during welding is considered in this model
Model Definition A symmetry is introduced to reduce the computational cost Instead of modeling the tool as a moving heat source, a moving coordinate system fixed to the tool axis is used Two infinite element domains , before and after the welding zone, are used to model an infinitely long plate Model geometry
Model Definition The rotating tool is divided into two parts: a pin with an inner contact, and a shoulder with a contact surface on the plate. The shoulder itself is not represented Model geometry
Model Definition Heat fluxes from friction with the rotating tool are taken into account on both contact surfaces. They account for the rotating speed and the normal force The heat fluxes from friction are set to 0 if the temperature exceeds the melting temperature Surface-to-ambient radiation as well as convection are considered on the plate Model boundary conditions
Model Definition The right side of the infinite plate, which corresponds to the supply side, is set to ambient temperature Model boundary conditions
Results In this configuration the maximum temperature is 935 K which is slightly higher than the melting temperature of aluminum (T=933 K) There is a thin film of aluminum that melts at the very surface in contact with the shoulder and the pin Cold material arrives on the welding tool as the plate moves Isothermal contours in the domain - In blue, the area where the temperature exceeds 933 K
Results The high temperatures created by the friction with the tool are then transported Isothermal contours in the domain - In blue, the area where the temperature exceeds 933 K
