Numerically modelled study of the plunge stage in friction stir spot welding using multi-tiered mesh partitions

Abstract Friction stir spot welding is a solid-state joining process that has attracted significant attention particularly in the field of lightweight, low melting alloys. These materials include alloys Aluminium and Magnesium amongst many others which are great importance to aerospace automobile industries. The friction complex thermo-mechanical multiphysics phenomenon currently intense research. motivation current study understand this behaviour by simulating it ABAQUS CAE environment. In technique, plunge stage identified as critical operation involves highly transient dynamic zone for material temperature flows. was studied detail using finite element based model. plasticity simulated Johnson-Cook model while frictional heat generation captured applying penalty-based contact between rotating tool workpiece surfaces. Considering reasonable assumptions made, results obtained numerical simulation were found agree with past experimental numerically modelled studies.