3-D transient analytical solution based on Green’s function to temperature field in friction stir welding

Friction stir welding (FSW) is a relatively modern welding process, which not only provides the advantages offered by fusion welding methods, but also improves mechanical properties as well as metallurgical transformations due to the pure solid-state joining of metals. The FSW process is composed of three main stages; penetrating or preheating stage, welding stage and cooling stage. The thermal history and cooling rate during and after the FSW process are decisive factors, which dictate the weld characteristics. In the current paper, a novel transient analytical solution based on the Green’s function method is established to obtain the three-dimensional temperature field in the welding stage by considering the FSW tool as a circular heat source moving in a finite rectangular plate with cooling surface and non-uniform and non-homogeneous boundary and initial conditions. The effect of penetrating/preheating stage is also taken into account by considering the temperature field induced by the preheating stage to be the non-uniform initial condition for the welding stage. Similarly, cooling rate can be calculated in the cooling stage. Furthermore, the simulation of the FSW process via FEM commercial software showed that the analytical and the numerical results are in good agreement, which validates the accuracy of the developed analytical solution.