Finite Element Simulation and Experimental Investigation of Friction Stir Welding of AA2219 and AA2014

Abstract

In FSW, a rotating cylindrical pin tool is forced to plunge in to the plates to be welded and moved along their contact line. The tool penetrates into the work pieces. During this operation, frictional heat that is generated by contact friction between the tool and workpiece. The plasticized material is stirred by the tool and forced to “flow “ to the side and the back of the tool as the tool advantages as  the temperature cools down, a solid continuous  joint between  the two plates  is  than formed.

In  this  project  work, DEFORM  -3D  is  used  to  perform  the  finite  element  analysis  and experimental  investigation on  the FSW  in order  to predict  residual  stresses,  temperatures, normal stresses and distortion of the welded structures, that are induced during FSW of  the given airframe structures made  up  of AA  2219  and AA  2014. A  new  technique  of  filling  friction  stir welding (FFSW) relying on a semi consumable joining tool has been developed to repair the keyhole left at the end of friction stir welding (FSW) seam. The FFSW process is able to repair the keyhole with both  metallurgical  and  mechanical  bonding  characteristics  and  the  FSW  seam  can  be  achieved without keyhole and other defects.