CFD modelling of friction stir welding (FSW) process of AZ31 magnesium alloy using volume of fluid method

In this work, a validate couple-thermo flow model of the FSW process is generated using the CFD software FLUENT, with this model, then being developed to model the flash formation phenomena that occur during the FSW process using the volume of fluid method. From both models, pressure distribution on the tool surface was predicted at different radial positions. A comparison was made between single and multiple phase flow models. A significant reduction of the pressure values was seen when using a two-phase flow model. Volume fraction contour showed the changing in the metal phase when increased the welding time steps. A modelling procedure of this work is presented in details to utilize it in the further numerical investigation as a guide. This work could be used to afford more understanding of surface flash formation phenomena. Moreover, the outcome of this study can be a useful technique to aid the tool failure and increase the tool life during the FSW process.