Control of the Weld Heterogeneity by Using a Novel Counter Variable Pin Shoulder Rotation Friction Stir Welding: A Simulation and Experimental Study

Abstract

Friction stir welding (FSW) produces inhomogeneous mechanical and metallurgical properties in the weld, which further require post-weld processing to control the heterogeneity. In the present study, the heterogeneity in the weld is reduced through counter-variable rotation friction stir welding (CVRFSW). The material flow and temperature distribution significantly affect the inhomogeneity of the FSWed properties which has been studied by developing a three-dimensional Lagrangian method-based viscoplastic model. The material flow, strain rate, and temperature distribution in conventional FSW (CFSW) and CVRFSW are studied quantitatively. The study revealed that CVRFSW improved joint strength and reduced the inhomogeneity of temperature, strain, and hardness. At a 10% lower shoulder speed than a pin, the weld strength improved by 16%. The simulation predicted that the temperature difference between the advancing side (AS) and the retreating side (RS) was 36 °C in CFSW, which was reduced to 8 °C in CVRFSW. Material deformation in CVRFSW occurred at a strain rate more than twice that of CFSW, and the asymmetry of strain rate between AS and RS reduced to one-fifth. Microstructures and their orientations of the welds were studied in detail. These findings contribute to the understanding of CVRFSW processes for enhanced weld quality and mechanical performance for industrial applications.