Numerical modeling of temperature fields during friction stir welding of the AA5083 aluminum alloy

One of the important parameters ensuring the production of a welded joint without continuity defects during friction stir welding is the provision of the required temperature in the metal bonding zone. Significant difficulties arise when determining experimentally the temperature directly in the stir zone of metals using thermocouples. In this regard, the application of numerical methods describing the distribution of temperature fields during friction stir welding is relevant. In the work, numerical modeling of temperature fields during friction stir welding was used, which was based on the finite element method using Abaqus/Explicit software. Modeling was carried out taking into account the coupled Euler – Lagrange approach, the Johnson – Cook plasticity model, and the Coulomb friction law. Using the finite element method, the models of a part, substrate, and tool were constructed taking into account their thermophysical properties. To reduce the computation time, an approach based on the metal mass scaling by recalculating the density of the metal and its thermal properties was used. The authors matched coefficients of scaling of the material mass and heat capacity for the selected welding mode parameters. To evaluate the validity of the results of numerical modeling of temperature fields during friction stir welding, the experimental research of the temperature fields using thermocouples was carried out. The paper shows the possibility of numerical modeling of temperature fields during friction stir welding with the help of the coupled Euler – Lagrange approach and Abaqus/Explicit software. Due to the application of the approach associated with material mass scaling, the calculation time is reduced by more than 10 times.