Modeling of defects in friction stir welding using coupled Eulerian and Lagrangian method

• Published in: Journal of manufacturing processes 2018-08, Vol.34, p.158-166
• Main Authors: Chauhan, Prashant, Jain, Rahul, Pal, Surjya K., Singh, Shiv B.
• Format: Article
• Language: English
• Subjects: Coupled Eulerian Lagrangian; Defects; Friction stir welding; Modeling
• ISSN: 1526-6125; 2212-4616
• DOI: 10.1016/j.jmapro.2018.05.022

[Display omitted] •Defect formation during friction stir welding process is modeled by using coupled Eulerian-Lagrangian method for different welding parameters.•Volume of fluid principle is used to predict the defect formation.•X-ray computer tomography, a non-destructive testing method is used to identify the defects within the welded sample.•A correlation between effective plastic strain and weld strength is proposed by using the concept of traction between the tool and workpiece. In the current research, a coupled Eulerian and Lagrangian method is used to model the friction stir welding process. Volume of fluid principle is used to predict the formation of defects during the process. Model is validated with experimentally observed spindle torque and axial force. Three different pin heights were simulated and pin height of 2.5 mm was found as the optimum value. Experimental defects are observed using the X-ray computer tomography method. The model has successfully predicted the presence of defect for different welding parameters. Defect free weld is produced at a tilt angle of 2°. Qualitative comparisons of effective plastic strain and welding efficiency were carried out and correlation among them is proposed.