A review on phenomenological model subtleties for defect assessment in friction stir welding

• Published in: Journal of manufacturing processes Vol. 120; pp. 641 - 679
• Main Authors: Das, Debtanay, Bag, Swarup, Pal, Sukhomay, De, Amitava
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 30.06.2024
• Subjects: Arbitrary Lagrangian Eulerian (ALE); Computational fluid dynamics (CFD); Coulomb's friction law; Coupled Eulerian and Lagrangian (CEL); Flash formation; FSW; Hook defect; Johnson-Cook model; Kissing bond defect; Lack of penetration; Norton's friction law; Norton-Hoff model; Nugget collapse; Sheppard-Wright model; Smoothed particle hydrodynamics (SPH); Surface galling; Tresca's friction law; Tunnel defect; Voids; Wormhole; Wormhole; Tunnel defect; Computational fluid dynamics (CFD); Kissing bond defect; Coupled Eulerian and Lagrangian (CEL); FSW; Sheppard-Wright model; Arbitrary Lagrangian Eulerian (ALE); Voids; Johnson-Cook model; Lack of penetration; Hook defect; Surface galling; Flash formation; Coulomb's friction law; Smoothed particle hydrodynamics (SPH); Norton's friction law; Tresca's friction law; Nugget collapse; Norton-Hoff model
• ISSN: 1526-6125; 2212-4616
• DOI: 10.1016/j.jmapro.2024.04.063

Friction stir welding (FSW) is in existence for well over three decades. Started primarily with the joining of aluminium alloys, FSW is gradually engaged for other alloys and also examined for additive manufacturing. The conventional experimental and theoretical studies on FSW focus on finding process parameters and tool geometry for producing a weld joint and ignores the insight for the evolution of defects. An appropriate comprehension of the mechanistic models to realize the underlying phenomena for the evolution of defects and assess their susceptibility to occur is required to enhance the application of FSW process. We present here a comprehensive review of the mechanistic models and, the constitutive and empirical relations with a focus on their substantive use for understanding the evolution of defects in FSW. Several associated factors such as tool-material interaction, computational complexity and accuracy, and the utility of commercial software are examined to present the subject. A thoughtful understanding about the mechanism of surface and volumetric defects is targeted through phenomenological behaviour of the process. We believe that this review work will provide a framework to help produce defect-free welds in FSW and allied solid-state joining processes.