A numerical strategy to identify the FSW process optimal parameters of a butt-welded joint of quasi-pure copper plates: modeling and experimental validation

Determining the optimal parameters of friction stir welding (FSW) process, which are suitable for a given joint configuration, remains great challenge and is often achieved through extremely time-consuming costly experimental investigations. The present paper aims to propose strategy identification butt-welded 3-mm thick quasi-pure copper plates. This based on FEM (finite element method) simulations temperature that supposedly known. A robust efficient finite model Coupled Eulerian-Lagrangian (CEL) approach has been adopted temperature-dependent coefficient used. Besides, mass scaling technique used significantly reduce simulation time. thermo-mechanical behavior was modeled using Johnson-Cook plasticity identified lab tests at different temperatures. results parametric study help define numerical surface response, this latter one can find parameters, advancing (va) rotational (vr) speeds, FSW process. response validated with good agreement between prediction results. Furthermore, investigations involving x-ray radiography, digital image correlation method, fracture analysis have helped better understanding effects welded quality.