Recent Advances in Numerical Simulation of Material Flow Behavior during Frictions Stir Welding

Friction stir welding(FSW) is a revolutionary welding technology for joining metallic materials such as aluminum alloys and magnesium alloys. The advantages of FSW over traditional fusion welding stem from the fact that material experiences severe plastic flow at temperatures below melting point. Therefore, it is critical to study and understand the material flow behaviors in order to optimize the FSW processing condition. Due to the spatial and temporal limitations of experimental studying, numerical simulation becomes an importance methodology in studying the material flow behavior. The basic physical processes involved in FSW process are analyzed. Thereafter, the numerical simulation on the material flow behavior is reviewed regarding the numerical method, heat source model, frictional boundary condition and constitutive model. Finally, the recent applications of the numerical models are discussed. In addition, the shortcomings in the current models and key points for the future researches are also pointed out.