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A fully coupled thermo-mechanical model is established to simulate the temperature variations and the material deformations in friction stir welding (FSW) of Ti-6Al-4V. The extracted data are used for further simulation on microstructural evolutions. A multi scale model, which consists of the grain growth model in grain cluster scale and the phase transformation model in one grain scale, is proposed. The nuclei of  α  and  β  phases, the recrystallizations and the grain growths are systematically investigated. Comparisons with experimental data and experimental observations can validate the newly proposed microstructural evolution model for Ti-6Al-4V. Results indicate that the volume fractions of  α  and  β  phases can be directly determined by the cooling rates in FSW process. With the increase of the rotating speed, the volume fraction of  α  phase is increased and  β  phase decreased due to the increase of welding temperature. With the decrease of the translational speed, the volume fraction of  α  phase gets bigger and  β  phase smaller. The acicular  α  grain can be generated on the  β  grain boundaries and grows along &lt;1 1 0&gt; direction on  β  substrate. The average length of  α  grain can be increased with longer cooling time and decreased with lower rotating speed or higher translational speed.

A Multi Scale Strategy for Simulation of Microstructural Evolutions in Friction Stir Welding of Duplex Titanium Alloy