Research on Failure Behavior Simulation Method of 6061 Aluminum Alloy Friction Stir Welding Joint

Zhu Xuewu1,2, Zhang Peng3, Yang Hang1,2, Yang Huawei1,2

（1. General Research and Development Institute, China FAW Group Co., Ltd., Changchun 130013;

2. State Key Laboratory of Comprehensive Technology on Automobile Vibration and Noise & Safety Control, Changchun 130013;

3. State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, Changsha 410082） Abstract：in this paper, the simulation method of failure behavior of 6061 aluminum alloy Friction Stir Welding (FSW) joint is studied. Considering the law of performance degradation of welds and heat- affected zones, the paper proposes a modeling method for accurately dividing different areas of the joint. Given different materials mechanical performance to different areas, a fine model of the tensile specimen of aluminum alloy FSW joint is established, and the validity of the fine model is verified through experiments. In order to ensure the calculation efficiency in the vehicle collision model, the paper proposes a method of transforming the fine model into an equivalent simplified model. The material properties and area division of the fine model are simplified and assigned to the equivalent model. The simulated peak force is in good agreement with the experimental results, which shows that the equivalent model can characterize the mechanical properties of FSW joint and meet the accuracy requirements. Key words: Friction Stir Welding(fsw), Fine model, Equivalent model, Simulation accuracy