Chapter 3
Modeling of Friction Stir Welding
Processes
N. Bhardwaj, R. Ganesh Narayanan, and U. S. Dixit
Abstract A review on the modeling of friction stir welding (FSW) is presented.
Modeling of FSW involves two main tasks—(1) modeling of heat transfer and (2)
modeling of plastic deformation. A few noteworthy analytical models are discussed;
however, these models make several approximations. Numerical modeling of FSW
can carry out reasonably accurate simulations of thermal, mechanical and a metallurgical phenomenon. Fundamentals of numerical models are described, and their
implementation is illustrated through an example of modeling of friction stir spot
welding process using a commercial software, viz. DEFORM-3D. Typical simulation results are presented to demonstrate the capability of modeling in predicting
thermal and mechanical response of a FSW process.
Keywords Friction stir welding · Modeling · Finite element method · Analytical
modeling · Welding · Simulation
3.1 Introduction
The friction stir welding (FSW), a solid-state welding technique, is a significant
development of the 1990s in the field of joining. In this process, the heat generated
due to friction and plastic deformation caused by a rigid tool rotating on and beneath
the surface of the workpiece is utilized to form the weld. Harmful gases, spatter
and arc flash get avoided in this process. It is more energy-efficient and economical
compared to conventional fusion welding techniques. The joints also benefit from
low thermal distortions and reduced hot cracking. Hot cracking refers to formation of
shrinkage cracks during solidification of weld metal. FSW occurs at a temperature
lower than the workpiece melting point, thus avoiding problems associated with
solidification of metal or excessive thermal expansion at high temperature [57]. It
is considered as a sustainable welding technique with increasing applications in
automobile, aerospace, shipbuilding and railways industries [12, 45].
N. Bhardwaj · R. Ganesh Narayanan · U. S. Dixit (B)
Department of Mechanical Engineering, Indian Institute of Technology, Guwahati, India
e-mail: uday@iitg.ac.in
© Springer Nature Switzerland AG 2021
J. P. Davim (ed.), Welding Technology, Materials Forming, Machining
and Tribology, https://doi.org/10.1007/978-3-030-63986-0_3
91
Modeling of Friction Stir Welding
Processes
N. Bhardwaj, R. Ganesh Narayanan, and U. S. Dixit
Abstract A review on the modeling of friction stir welding (FSW) is presented.
Modeling of FSW involves two main tasks—(1) modeling of heat transfer and (2)
modeling of plastic deformation. A few noteworthy analytical models are discussed;
however, these models make several approximations. Numerical modeling of FSW
can carry out reasonably accurate simulations of thermal, mechanical and a metallurgical phenomenon. Fundamentals of numerical models are described, and their
implementation is illustrated through an example of modeling of friction stir spot
welding process using a commercial software, viz. DEFORM-3D. Typical simulation results are presented to demonstrate the capability of modeling in predicting
thermal and mechanical response of a FSW process.
Keywords Friction stir welding · Modeling · Finite element method · Analytical
modeling · Welding · Simulation
3.1 Introduction
The friction stir welding (FSW), a solid-state welding technique, is a significant
development of the 1990s in the field of joining. In this process, the heat generated
due to friction and plastic deformation caused by a rigid tool rotating on and beneath
the surface of the workpiece is utilized to form the weld. Harmful gases, spatter
and arc flash get avoided in this process. It is more energy-efficient and economical
compared to conventional fusion welding techniques. The joints also benefit from
low thermal distortions and reduced hot cracking. Hot cracking refers to formation of
shrinkage cracks during solidification of weld metal. FSW occurs at a temperature
lower than the workpiece melting point, thus avoiding problems associated with
solidification of metal or excessive thermal expansion at high temperature [57]. It
is considered as a sustainable welding technique with increasing applications in
automobile, aerospace, shipbuilding and railways industries [12, 45].
N. Bhardwaj · R. Ganesh Narayanan · U. S. Dixit (B)
Department of Mechanical Engineering, Indian Institute of Technology, Guwahati, India
e-mail: uday@iitg.ac.in
© Springer Nature Switzerland AG 2021
J. P. Davim (ed.), Welding Technology, Materials Forming, Machining
and Tribology, https://doi.org/10.1007/978-3-030-63986-0_3
91