A new smoothed particle hydrodynamics non-Newtonian model for friction stir welding: Process modeling and simulation of microstructure evolution in a magnesium alloy

• A novel Lagrangian-particle-based simulation model for friction stir welding.
• Correctly capturing the essential dynamics of friction stir welding.
• A general numerical approach for a diverse range of viscoplastic materials involved in various dynamic processes

We present a new smoothed particle hydrodynamics (SPH) model for friction stir welding (FSW). FSW has broad commercial application in the marine, aerospace, rail, and automotive industries. However, development of the FSW process for each new application has remained largely empirical. Few established numerical modeling techniques have been developed that can explain and predict important features of the process physics involved in FSW. This is particularly true in the areas of material flow and mixing mechanisms. In this paper, we present a novel modeling approach to simulate FSW that may have significant advantages over current finite element or finite difference based methods. Unlike traditional grid-based methods, Lagrangian particle methods such as SPH can simulate the dynamics of interfaces, large material deformations, and the material’s strain and temperature history without employing complex tracking schemes. Three-dimensional simulations of FSW on AZ31 Mg alloy are performed. The temperature history and distribution, grain size, microhardness as well as the texture evolution are presented. Numerical results are found to be in good agreement with experimental observations.