ANALYSES EXPERIMENTALES ET NUMERIQUES DU PROCEDE DE SOUDAGE PAR FRICTION MALAXAGE FSW

Abstract : The Friction Stir Welding (FSW) is a solid state welding process, without melting. The weld is fabricated thanks to the action of tool made of a shoulder and a pin, positioned at the interface of the two pieces to be welded. The tool as two roles : heating of the material by friction of the shoulder, mixing of the material due to the pin. This thesis work is made within the partnership between Arts et Métiers ParisTech and Institut de Soudure. Its goal is to develop a FSW simulation model in order to decrease experimental trials required to optimize the process. Therefore, some points have been treated in this manuscript. Experimental analysis of thermal cycles and material movements in the case of unthreaded tools has been carried out. This situation allows (1) to make the comparison with numerical simulation easier and (2) to be in the case of worn tools. Formulations (lagrangian, eulerian, ALE) analysis in order to choose the more appropriate to take material flow into account has allowed to select an eulerian formulation (implemented in the FLUENT software) to estimate thermal and kinematical fields in the steady state. The set up of the numerical model in the FLUENT software is presented. We have studied the influence of numerical parameters on the results and proposed an identification strategy for some parameters which are not reachable experimentally. A detailed comparison between our experimental results and the ones from our simulations have been performed with success. The study of the influence of the process parameters (feed rate, rotating speed) and of the pin geometry on the kinematical and thermal fields has highlighted the link between velocity field and the presence of tunnel type defects.
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Submitted on : Saturday, September 4, 2010 - 6:53:48 PM
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Olivier Lorrain. ANALYSES EXPERIMENTALES ET NUMERIQUES DU PROCEDE DE SOUDAGE PAR FRICTION MALAXAGE FSW. Mécanique [physics.med-ph]. Arts et Métiers ParisTech, 2010. Français. ⟨NNT : 2010ENAM0014⟩. ⟨pastel-00515112⟩

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