Advanced FEM Modeling of Friction Stir Welding of Ti6Al4V: Microstructural Evolutions

Friction Stir Welding (FSW) is a solid state welding process patented in 1991 by TWI; initially adopted to weld aluminum alloys, is now being successfully used also for high resistant materials. Welding of titanium alloys by traditional fusion welding techniques presents several difficulties due to high material reactivity resulting in bonding with oxygen, hydrogen, and nitrogen with consequent embrittlement of the joint. In this way FSW represents a cost effective and high quality solution. The final mechanical properties of the joints are strictly connected to the microstructural evolutions, in terms of phase change, occurring during the process. In the paper a 3D FEM model of the FSW welding process, based on a thermo-mechanical fully coupled analysis, is presented. The model, tuned both for the thermo mechanical analysis and the phase transformation through experimental data, is able to predict the phase volume fraction of each joint typical zone at the varying of the main process parameters. The obtained results permit to assess that the tuned FEM model of the FSW process can be utilized as an effective design tool