A three-dimensional heat transfer model for friction stir welding (FSW) is presented in this paper; a moving coordinate is introduced to reduce the difficulty of modeling the moving tool. Heat input from the tool shoulder and the tool pin are considered in the model. The finite difference method was applied in solving the control equations. A non-uniform grid mesh is generated for the calculati...

A three-dimensional numerical model is used to simulate the Friction Stir Welding (FSW) process using the computational fluid dynamics package ‘FLUENT’. Two mechanical models: the Couette and the Visco-Plastic fluid flow models for Al-6061-T6 were simulated. The simulation results are compared to experimental data for Al 6061-T6 welded at high rotational (1500–5000 rpm) and travel speeds rangin...

Metal Matrix Composites (MMCs) consist of a metal alloy reinforced with ceramic particles or fibers. These materials possess a very high strength to weight ratio, good resistance to impact and wear, and a number of other properties which make them attractive for use in aerospace and defense applications. MMCs have found use in the space shuttle orbiter's structural tubing, the Hubble Space Tele...

Friction stir welding (FSW) is a promising technique to join aluminum alloys without having problems encountered during fusion welding processes. In the present work, the evolution of microstructure and texture in friction stir welded thin AA2024 aluminum alloy are examined by electron backscattered diffraction (EBSD) technique. The sheets with 0.8 mm thickness were successfully welded by frict...

Friction stir welding (FSW) is a recently developed solid-state joining process that uses a specially shaped rotating tool to produce lap or butt joints. At the National Research Council, an inter-institute collaboration was started in 2007 with the goal of exploiting the NDE expertise and applying it for the characterization of friction stir welds for various industrial applications. In partic...

the objective of this study was to develop a numerical model for the prediction of temperature distribution, effective plastic strain distribution, and especially material flow in friction stir welding of copper plates. the deform-3d software was used by incorporating a lagrangian incremental formulation. threedimensional results of the material flow pattern which were extracted using the point...

This paper presents a systematic approach to develop the mathematical model for predicting the ultimate tensile strength, yield strength, and percentage of elongation of AA6351 aluminum alloy which is widely used in automotive, aircraft and defense Industries by incorporating (FSW) friction stir welding process parameter such as tool rotational speed, welding speed, and axial force. FSW has bee...

Friction stir welding (FSW) can be defined as a green technology, because the consumption of energy during this process is less than other welding methods. In addition, during the process there is no gas, filler material or other consumables. It should be noted that, complex curved shapes are now commonly used in different industries in a bid to have lightweight structures. According to the abo...

Friction stir welding (FSW) is a relatively new welding process that may have significant advantages compared to the fusion processes as follow: joining of conventionally non-fusion weldable alloys, reduced distortion and improved mechanical properties of weldable alloys joints due to the pure solid-state joining of metals. In this paper, a three-dimensional model based on finite element analys...

Different methods have been applied to refine various characteristics of the zone (or nugget) obtained by friction stir welding (FSW). In the current research, joining components are vibrated normal to the weld line during FSW to refine the zone microstructure. This process is described as friction stir vibration welding (FSVW). The effect of FSVW on mechanical properties, corrosion behavior, a...