Design of the friction stir welding tool using the continuum based FEM model

In friction stir welding (FSW), the welding tool geometry plays a fundamental role in obtaining desirable microstructures in the weld and the heat-affected zones, and consequently improving strength and fatigue resistance of the joint. In this paper, a FSW process with varying pin geometries (cylindrical and conical) and advancing speeds is numerically modeled, and a thermo-mechanically coupled, rigid-viscoplastic, fully 3D FEM analysis able to predict the process variables as well as the material flow pattern and the grain size in the welded joints is performed. The obtained results allow finding optimal tool geometry and advancing speed for improving nugget integrity of aluminum alloys.