Papers abstract:

A model of friction stir spot welding (FSSW) between aluminum alloy 6061-T6 and TRIP 780 steel is developed in this work based on the Coupled Eulerian-Lagrangian (CEL) method, which considers the material flow at the dissimilar material interface and also the interaction between the welding tool and workpiece. The cross-sectional view from the numerical result agrees well with the experimental observations. The material distribution at different plunge depths calculated by the model illustrates the formation of the hook during the welding process. The force and thermal history generated by the numerical work also correspond well with the experimental data. A force history generated through a tool with a smaller shoulder diameter is studied to further validate the model. The developed model can be useful for better understanding the effect of the welding tool on FSSWand optimization of the tool geometry.

Product Overview:
This tutorial provides a comprehensive step-by-step guide for setting up friction stir spot welding simulations using the ALE method. By refining material properties, optimizing meshing, and employing ALE techniques, the model achieves accurate temperature, stress, and deformation predictions. The tutorial also emphasizes computational efficiency and result validation techniques, making it an essential resource for researchers and engineers in welding simulations. Key simulation steps include:

• The tutorial demonstrates spot welding using the friction stir method.
• While the referenced paper focuses on the Coupled Eulerian-Lagrangian (CEL) approach, the tutorial uses the Arbitrary Lagrangian-Eulerian (ALE) method.
• Without ALE, results would be inaccurate due to excessive distortion.
• X-ray images are referenced to analyze the results of friction stir spot welding (FSSW).

In this tutorial, the Thermal-mechanical modeling on friction stir spot welding of dissimilar materials based on Coupled Eulerian-Lagrangian approach is simulated, according to data from the works of Chen et al., Thoppul and Gibson, and Chauhan et al.