Coupled Themo-Elasto-Viscoplastic Modeling of Friction Stir Welding in Eulerian Frame

A coupled 2-dimensional Eulerian thermo-elasto-visco-plastic model has been developed for modeling the Friction Stir Welding process. First, a coupled thermo-visco-plastic analysis is performed to determine the temperature distribution in the full domain and the incompressible material flow around the spinning tool. Next, an elastovisco-plastic analysis is performed outside the visco-plastic region to comput the residual stress. Both frictional heat and plastic deformation heat generation are considered in the model. Furthermore, this is the only known model computing residual stress accounting for plasticity caused by both thermal expansion and mechanical deformation due to material spinning. The computed residual stress is verified by comparing to experimentally measured data.