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<p>The main objective of this paper is to propose a suitable equivalent heat source that allows simulating transient FSW welding of thick structures with commercial finite element codes. At first, a fully coupled thermo-fluid model is developed by using the Rigid-ALE formalism in the case of a but joint of 20&#xa0;mm thick. This quasi-stationary model is calibrated from experimental measurements in terms of Taylor-Quinney coefficient and heat exchange with the backing plate. This identification is carried out by means of an optimization algorithm with Python programming language. From these numerical results, different shapes of equivalent heat source are investigated for simulating the thermal field without accounting for the material stirring. To the authors’ knowledge, such a modeling strategy has never been reported before in the literature, especially for thick joints. Based on these results, a suitable version of the heat source proposed by Goldak et al. (Metall Trans B 15:299–305, <CitationRef CitationID="CR2">1984</CitationRef>) is proposed. It is shown that the new heat source has the ability to model very satisfactory the thermal gradient in the thickness of the joint during welding.</p>

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A suitable equivalent heat source for the transient simulation of thick FSW joining

  • 期刊论文

  • 发表日期：

    2025年3月7日

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  • Rodrigue Urvoy,
  • Eric Feulvarch

摘要

The main objective of this paper is to propose a suitable equivalent heat source that allows simulating transient FSW welding of thick structures with commercial finite element codes. At first, a fully coupled thermo-fluid model is developed by using the Rigid-ALE formalism in the case of a but joint of 20 mm thick. This quasi-stationary model is calibrated from experimental measurements in terms of Taylor-Quinney coefficient and heat exchange with the backing plate. This identification is carried out by means of an optimization algorithm with Python programming language. From these numerical results, different shapes of equivalent heat source are investigated for simulating the thermal field without accounting for the material stirring. To the authors’ knowledge, such a modeling strategy has never been reported before in the literature, especially for thick joints. Based on these results, a suitable version of the heat source proposed by Goldak et al. (Metall Trans B 15:299–305, 1984) is proposed. It is shown that the new heat source has the ability to model very satisfactory the thermal gradient in the thickness of the joint during welding.