Finite element simulation of an AA2024-T3 friction stir weld

This paper presents a three-dimensional sequentially coupled thermo-mechanical analysis of the friction stir welding process suitable for residual stress prediction. A friction stir butt weld of the aluminium alloy 2024 T3 is simulated using finite element analysis. The thermal model includes diffusive heat transfer in the work pieces and that backing plate, convective heat transfer in the work pieces caused by the material flow, heat generation at the tool, heat loss to the ambient air and heat transfer between the work pieces and the backing plate. The mechanical model includes thermal expansion and tool forces acting on the work pieces. The thermal part of the simulation shows encouraging results concerning the capability to accurately simulate the temperature distribution. The simulated temperatures correspond well to experimentally measured temperatures and the non-symmetric temperature distribution due to material flow is accurately captured in the simulation.