Finite element modeling of laser assisted friction stir welding of carbon steels for enhanced sustainability of welded joints

Abstract

In Friction stir welding (FSW) of carbon steels, process parameters must be set to avoid defects such as warm holes. Proper selection of process parameters also affects the final grain microstructure and phase transformations and, ultimately, the weld’s mechanical properties. Process parameters, including laserassisted heating, of AISI 1045 carbon steel were investigated via a 3D finite element method (FEM) model. The laser action was modeled as heat source with constant flux. The simulation findings favorably agree with experiments reported in the literature and suggesting that with laser-assisted-FSW welding can be performed at higher traverse speeds (400 vs. 100 mm/min) while maintaining defect free weld. Also, evolved phase transformations are predicted across the weld geometry as time progresses. Such findings will help in the prediction of sound welding parameters and in estimating the mechanical properties of the various regions of the weld leading to more sustainable joints.