A study on material flow pattern in friction stir welding using finite element method

Abstract

In this article, numerical modelling of friction stir welding of copper plates is presented. The aim of this study is to implement DEFORM-3D for developing the numerical simulation. Material flow patterns are extracted using point tracking method, and mechanical/metallurgical properties of workpiece are analysed. Simulation results suggest that material particles in front of the tool pin tend to pass and settle behind the pin from the retreating side. Based on the results, a new classification of distinctive zones in the stirred zone is presented. The stir zone shape in friction stir welding is divided into five distinctive zones. In friction stir welding of copper metals, the stir zone does not lean completely towards any sides of the welding line, which was found to compare favourably with experimental observations.