Numerical Analysis on Friction Stir-Processed Nickel 200 Alloy Plate with Al2O3 Reinforcement

The present work focuses on the multiphysics modeling on friction stir processing (FSP) on Nickel (Ni) 200 workpiece with Al2O3 particle intermixing. The three-dimensional (3D) heat transfer analysis coupled with fluid flow physics used to estimate the temperature rise and fluid flow during FSP of Ni matrix with Al2O3 reinforcement. The Al2O3 domain of size 1 mm width and 1.2 mm depth is model inside the Ni 200 plate of 3 mm thick. The level set (LS) method is used to establish the mixing between two fluids (Ni 200 and Al2O3). The leading edge of the FSW tool becomes hotter as a result of the development of a high-pressure zone at the location where the tool tip and workpiece contacts. The Al2O3 particles traveled toward the retreating side (RS) of the tool while it was rotating, and as it advanced, the particles broke off and gathered on the advancing side (AS). The proximity to the shoulder surface led to a significant concentration of particles due to the strong influence of the shoulder.