Understanding the important material effects in a 2-D model will give insight into the necessary effects that should be used in a 3-D model. This will help create better models of Friction Stir Welding that will have the capability to optimize the input parameters in a quick and cost effective manner.
Cornell University has developed a finite element code that has been used in other large deformation applications such as metal rolling. It currently is being modified to model friction stir welding at steady state conditions. The code has the capability of modeling work hardening, thermo softening, and visco-plastic material, which will soon be an elastic visco-plastic model.
Plates have been instrumented with thermocouples in order to validate the models temperature field. More validation test will be run in the future.
Results and Discussion
The predicted results from a wide variety of input parameters have been generated by the 2-D model and are shown below.
Viewing Rectangle = 1 by 1 inch
Pin Diameter = .4 inch