Thermo-Mechanical Modelling of Friction Stir Processing of AZ91 Alloy: Using Smoothed-Particle Hydrodynamics

A thermo-mechanical model of friction stir processing (FSP) using the Altair based on meshless Smoothed-Particle Hydrodynamics (SPH) was developed and verified experimentally. Process parameters adopted for both experimentation simulation during FSP AZ91 were 1000 rpm tool stirring speed, 40 mm/min advancing 0° tilt angle. The numerical analysis predicted temperature distribution material movement in three phases: plunging, dwelling, traversing. Simulated temperatures traversal phase found to be greater than experimental Ti32 thermal camera as heat only transported by plastic deformation. Peak all phases observed range 47% 87% material’s melting point are accordance with findings experiments. SPH mesh-free proven capable predicting in-process thermal-mechanical state variables after process extracting morphology. around has been node tracking, which further anticipates that there no complete flow nodes from RS AS, leaving a gap must filled. Post-processed morphology shows inadequacy due lower compressive force. It formed wormhole at side’s trailing