Modelling of precipitation during friction stir welding of an Al-Mg-Si alloy

Abstract

In this study, microstructural evolution in AA 6082-T651 friction stir welds is simulated using a metallurgical model coupling a Monte Carlo random sampling technique and classical nucleation and growth theory. The calculated volume fraction and size distribution of precipitates are used to predict hardness. Some of the model parameters are calibrated from microstructure and hardness data available in the open literature. Temperature and hardness data in the region of the weld are obtained from FSW experiments. The temperature in the weld is predicted by finite element analysis, with a simplified thermo-mechanical approach, after calibration of heat transfer parameters in order to match the temperature measurements. The calculated thermal cycles are then applied to the metallurgical model. The subsequently predicted hardness profiles across the weld are then compared with experimental data.