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Advanced Modeling of Friction Stir Welding – Improved Material Model for Aluminum Alloys and Modeling of Different Materials with Different Properties by Using the Level Set Method

S. Dörfler
Wilhelm Gronbach GmbH, Wasserburg a. Inn, Germany

Friction Stir Welding (FSW) has gained much importance throughout the last years. Beside comprehensive experimental work that has been carried out, the simulation of the welding zone is of major interest.  Due to the high strains observed within the welding zone, the Eulerian (CFD) approach seems to be the most promising for the prediction of flow around the FSW tool. However, the CFD modeling of FSW still faces some problems.

This paper introduces an advanced CFD model for the simulation of friction stir welding of different aluminum alloys. To model the welding of different materials, the use of level set method will be introduced to friction stir welding. With that it becomes possible to predict material mixing within the weld seam.