Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

Friction stir welding of roll-plated precursor material and aluminium sheet metal for the production of aluminium-foam-sandwich structures

Datum: 23.06.2009



  • Prof. i.R. Dr.-Ing. Dr.-Ing. E.h. mult. Dr. h.c. mult. M. Geiger
  • Prof. Dr.-Ing. H. Meerkamm

Within the scope of this work, basic phenomena observed during friction stir welding have been clarified with numerical simulations as well as experimental work. To improve the understanding of the complex physical interactions within the welding zone, existing numerical approaches for friction stir welding had to be amended by a phenomenological constitutive law connected to the Navier-Stokes-Equations and thus connected to the level-set-approach. This improved model enables the prediction of the complex stirring process including the mixing of different aluminium alloys within the welding zone and helps to explain phenomena, observed during practical experiments. The modelling approach of this work is not only limited to the simulation of the friction stir weling process, but can easily be adapted to other manufacturing processes by changing the boundary conditions. Precondition for that are similar conditions concerning temperature, strain and strain rate. As an example and outlook, the thesis introduces the reader to the modelling of the metal coextrusion process.