Elucidation of solid-state metal flow behaviors during friction stir welding: Numerical and experimental investigation

Abstract

During the process of friction stir welding, the behavior of interfacial friction holds a pivotal role in shaping both the heat generation and material flow within the workpiece. However, a quantifiable comprehension of how the friction between the tool and the workpiece (T/W) precisely influences the interface contact state and the heat generation, and the material flow remains elusive. This paper strives to address this gap by introducing a mathematical model that couples interface friction and material flow through the utilization of a shear stress boundary condition at the T/W interface, which is able to present sliding and sticking condition, in our computational fluid dynamics simulation. Notably, the simulation underscore a non-uniform distribution characterizing the friction interface contact state. It is found that augmenting the coefficient of friction (CoF) induces a transition from sliding to sticking both locally and averagely at the T/W interface. When the friction interface becomes predominantly characterized by a sticking state, the CoF exerts a nominal influence over the overall heat generation, yet maintains a discernible impact on material flow patterns. This foundation enables the elucidation of the mechanism through which the friction interface contact state impacts material flow behavior. The simulated material flow trajectory also highlight that under a sliding-dominated friction interface, materials simply flow around the tool. The material flow trajectories on the advancing side (AS) and the retreating side (RS) are approximately symmetrical. The materials driven by the shoulder and the pin are converged at the center of the weld behind the tool. Simulation and experimental results demonstrate that under a sticking-dominated friction interface, materials tend to undertake multiple circulations around the tool and migrate downward to the AS. Other materials are observed to migrate upward to the RS. The entrance point for this circular behavior resides in the AS situated beneath the shoulder.