Numerical Simulation of AA2024-T3 Friction Stir Welding (FSW) Process: Sensitivity Analyses and Influence of Decisions during Modelling Stages

Abstract

The main objective of the present work is to assess the influence of several parameters relevant for Finite Element Analysis (FEA) in modelling Friction Stir Welding (FSW) processes on AA2024-T3 plates. Several tests were performed including variations on the type of shell elements, number of integration points across thickness direction and mesh refinement levels, aiming for good accuracy and low computational cost. On the one hand, several setups of the mechanical boundary conditions, modelling the clamping systems, were also tested, leading to the conclusion that the results, in terms of longitudinal residual stresses, are significantly affected by this factor. On the other hand, variations on the heat input distribution showed a reduced effect, or almost null, on the final results.