A Review on Friction Stir Welding/Processing: Numerical Modeling

Area of Science:

• Manufacturing Engineering
• Materials Science
• Computational Mechanics

Background:

• Friction stir welding (FSW) joins metals in a solid state, offering unique properties valuable across industries.
• Experimental study of FSW weld zones is difficult due to severe plastic deformation, hindering analysis of temperature, stress, and material flow.
• Numerical methods provide a viable approach to investigate these complex FSW parameters.

Purpose of the Study:

• To present a comprehensive review of numerical analysis techniques for friction stir welding (FSW).
• To focus on the applicability of these numerical methods in component manufacturing.
• To examine the advantages and limitations of various simulation approaches for FSW.

Main Methods:

• Review of numerical methods including Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD).
• Analysis of simulation approaches for modeling material flow, temperature distribution, and stress state in FSW.
• Discussion of crucial variables influencing numerical modeling of the FSW process.

Main Results:

• Identification of various numerical techniques suitable for FSW simulation.
• Evaluation of the strengths and weaknesses of different modeling approaches.
• Highlighting the role of numerical analysis in predicting defect-prone zones within FSW joints.

Conclusions:

• Numerical modeling is crucial for understanding and optimizing the FSW process.
• The review provides insights into selecting appropriate simulation techniques for FSW applications in manufacturing.
• Advancements in numerical analysis enhance the predictability and reliability of FSW components.