Entire Process Simulation of Friction Stir Welding — Part 1: Experiments and Simulation

Understanding structure-parameter-property relationships in friction stir welding of aluminum alloys is a challenge despite its wide application in load-bearing components. In this paper, we propose a combined strategy for mapping the macro- and microstructural responses of these joints. A combined model based on experiment validation was adopted for the prediction of tensile strength. This included the computational fluid dynamics model, precipitation evolution model, dynamic recrystallization and recovery model, and computational solid mechanics model. The comparison between the experimental results and the combined model proved the rationality and accuracy of this numerical model.