Multiphysics Integrated Modeling of Self-Reacting Friction Stir Welding

As an advanced variant of friction stir welding (FSW), self-reacting friction stir welding (SRFSW) utilizes a double-sided tool and self-contains the high forging force. This makes the process ideally suitable for joining large-scale aerospace components and provides promising solutions for in-space manufacturing. However, the current route for SRFSW process development is highly empirical. The goal of this project is to provide a high fidelity physics-based predictive model that describes process-microstructure-property relationships during SRFSW and enables virtual and rapid process optimization. More specifically, a fully microstructure-integrated thermo-mechanical process model will be developed within a hybrid solid-fluid framework, in which the material constitutive law explicitly considers dynamic recrystallization. Critical parameters will be obtained through precisely controlled thermo-mechanical material testing. Precipitates evolution and property models are further incorporated to build a holistic computational tool that inputs SRFSW tooling information, process conditions and outputs weld properties.

The SRFSW process is ideally suitable for joining large-scale aerospace components and provides promising solutions for in-space manufacturing.

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