Engineering Transactions, 62, 4, pp. 313–328, 2014

Nonlinear Finite Element Simulation of Friction Stir Processing of Marine Grade 5083 Aluminum Alloy

Emad Eldin KISHTA

United Arab Emirates

Farid ABED
American University of Sharjah Department of Civil Engineering
United Arab Emirates

Basil DARRAS
American University of Sharjah Department of Mechanical Engineering
United Arab Emirates

As friction stir processing is emerging as a new technique for material enhancement, full understanding of the process has not been achieved yet. The resulting mechanical and microstructural properties are controlled by processing parameters like rotational and translational speeds. To support experimental results, it is very necessary to develop robust finite element models that can simulate the friction stir welding process and predict the effect of the processing parameters on the thermal profiles. This, in turn, gives a forecast of the expected tensile and microstructural properties of the alloy used. This paper presents a thermomechanical-based finite element modeling adopting a coupled Eulerian Lagrangian formulation to simulate the friction stir process for Marine Grade AA5083. A set of friction stir welding tests considering different rotational and translational speeds is also conducted in this study to verify and validate the present FE modeling. The thermal profiles as well as the peak temperatures measured experimentally using infra-red imaging technique were successfully predicted by the proposed FE modeling.
Keywords: friction stir processing; nonlinear finite element; Eulerian-Lagrangian formulation; temperature profile; aluminum.
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