A novel 3D model was developed to study the effects of process parameters on the friction stir welding (FSW) of Al-SiC composites with regards to residual stresses and peak temperatures. An arbitrary Lagrangian–Eulerian formulation and remeshing were employed to account for large plastic deformations. The thermal history of the workpiece was used to define a coupled thermo-mechanical model. Al-SiC sheets were welded via the FSW method, and the resulting residual stress profiles were consistent with the results for the same test cases obtained via the developed model. The maximum magnitudes of the residual stresses were then used to quantitatively validate the model with the experimental results. The results show that at different transverse speeds, the rotation rates had dissimilar effects on the residual stresses of the post-welded sheets. The effect was dependent on whether the peak temperatures achieved in each case exceeded the Al-SiC precipitate dissolution temperature. This was further confirmed with the temperature distribution profiles obtained by the same model.

开发了一种新的 3D 模型来研究工艺参数对 Al-SiC 复合材料搅拌摩擦焊 (FSW) 的残余应力和峰值温度的影响。使用任意的拉格朗日-欧拉公式和重新网格化来解释大的塑性变形。工件的热历史用于定义耦合的热机械模型。Al-SiC 片材通过 FSW 方法焊接，所得残余应力分布与通过开发模型获得的相同测试案例的结果一致。然后使用残余应力的最大量值来用实验结果对模型进行定量验证。结果表明，在不同的横向速度下，转速对焊后板的残余应力有不同的影响。效果取决于在每种情况下达到的峰值温度是否超过了 Al-SiC 沉淀物溶解温度。同一模型得到的温度分布曲线进一步证实了这一点。