Three-dimensional heat and material flow during friction stir welding教程.pdfVIP

Acta Materialia 55 (2007) 883–895 Three-dimensional heat and material flow during friction stir welding of mild steel R. Nandan a,*, G.G. Roy a, T.J. Lienert b, T. Debroy a a Department of Materials Science and Engineering, The Pennsylvania State University, University Park, PA 16802, USA b Materials Science and Technology, Los Alamos National Laboratory, Los Alamos, NM, USA Received 15 April 2006; received in revised form 3 September 2006; accepted 7 September 2006 Available online 4 December 2006 Abstract Three-dimensional viscoplastic flow and heat transfer during friction stir welding of mild steel were investigated both experimentally and theoretically. The equations of conservation of mass, momentum and energy were solved in three dimensions using spatially variable thermo-physical properties and a methodology adapted from well-established previous work in fusion welding. Non-Newtonian viscosity for the metal flow was calculated considering temperature and strain rate dependent flow stress. The computed results showed significant viscoplastic flow near the tool surface, and convection was found to be the primary mechanism of heat transfer in this region. Also, the results demonstrated the strong three-dimensional nature of the transport of heat and mass, reaffirming the need for three-dimensional calculations. The streamlines of plastic flow indicated that material was transported mainly along the retreating side. The computed tem- peratures were in good agreement with the corresponding experimentally determined values. 2006 Published by Elsevier Ltd on behalf of Acta Materialia Inc. Keywords: Friction sti