Simulation of Temperature and Residual Stress Field in Friction Stir Welded AISI 304 Stainless Steel Joints

Three-dimensional nonlinear thermal and thermo-mechanical numerical simulations are conducted for the friction stir welding of AISI 304 stainless steel. The finite element analysis code SYSWELD was used to simulate the results using inverse approach. Defect free welds were made experimentally using a rotational speed, welding speed and shoulder diameter of 800 rpm, 90 mm/min and 20 mm respectively. Residual stress measurement was carried out with X-ray stress analyzer employing C_rK_α radiation. The transient temperature fields were obtained by finite element simulation and the residual stresses in the welded plate are calculated using a three-dimensional elastic–plastic thermo-mechanical simulation. The results of the simulation are in good agreement with that of experimental results.