A numerical strategy to identify the FSW process optimal parameters of a butt-welded joint of quasi-pure copper plates: modeling and experimental validation.

Determining the optimal parameters of the friction stir welding (FSW) process, which are suitable for a given joint configuration, remains a great challenge and is often achieved through extremely time-consuming and costly experimental investigations. The present paper aims to propose a strategy for the identification of the optimal parameters for a butt-welded joint of 3-mm thick quasi-pure copper plates. This strategy is based on FEM (finite element method) simulations and the optimal temperature that is supposedly known. A robust and efficient finite element model that is based on the Coupled Eulerian-Lagrangian (CEL) approach has been adopted and a temperature-dependent friction coefficient has been used. Besides, the mass scaling technique has been used to significantly reduce the simulation time. The thermo-mechanical behavior of the butt-welded joint was modeled using a Johnson-Cook plasticity model that was identified through lab tests at different temperatures. The results of the parametric study help to define the numerical surface response, and based on this latter one can find the optimal parameters, advancing (v_a) and rotational (v_r) speeds, of the FSW process. This numerical surface response has been validated with good agreement between the numerical prediction of the model and the experimental results. Furthermore, experimental investigations involving x-ray radiography, digital image correlation method, and fracture surface analysis have helped a better understanding of the effects of FSW parameters on the welded joint quality. [ABSTRACT FROM AUTHOR]