Workshop: Simulation Friction Stir Welding By Using Sph Method In Abaqus Thermal Analysis

The friction stir welding (FSW) process is increasingly used as the preferred method for joining aluminum alloys. This solid-state technique produces high-quality welds with excellent efficiency. Because the process avoids melting and solidification, many defects common in conventional fusion welding are eliminated.

However, depending on the process parameters, FSW joints may still develop volumetric defects that reduce the strength of the weld. In this tutorial, the simulation of friction stir welding using the Smoothed Particle Hydrodynamics (SPH) method in Abaqus thermal analysis is presented.

Abaqus does not directly support SPH elements coupled with temperature degrees of freedom (such as the PC3DT element). To address this, temperature was applied to these elements through specific adjustments.

The analysis consists of three steps. During each step, both stress and temperature distributions change. Figures from the simulation are shown below to illustrate the results.