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Detailed multi-physics modelling of friction stir welding

Objective

The objective of DEEPWELD is to develop a multi-physics multi-scale numerical tool for simulating the FrictionStir Welding process, that will be able to obtain accurate predictions of residual stresses, weld properties andtool loads. The new tool will be a large step forward compared to current thermo-mechanical solutions, indeedthe latter depend on well calibrated heat fluxes used as energy input in the model. These heat fluxes must beobtained by measurements of data during experiments. This prevents op timisation of the process parametersand real usage of the FSW simulation system in a design environment for predictive simulation of the behaviourof parts.A novel approach will be followed in DEEPWELD. A detailed simulation of the material flow around th e tool willbe coupled to a simulation of the complete welding process. The software developments forming the core ofDEEPWELD will be focussed on: a material flow solver capable of simulating the material flow around the tool; coupling of the material flo w solver to existing but modified industrial FE codes; this will allow the use ofall existing features of the industrial codes to handle industrial applications and ease exploitation of thenew tool in the industrial environment. since the temperature wil l strongly affect the rheology of the material, a material model (metallurgy)capable of dealing with the large variations in material properties throughout the weld region will bedeveloped and implemented; furthermore, an appropriate friction law which d escribes the behaviour at the interface between tool andweld material needs to be implemented.DEEPWELD also involves a strong experimental part. Experiments will be conducted at two levels to obtain onone hand the required input data for the simulation such as accurate reologhical material properties, improvedmetallurgy models, friction models, material flow visualization and on the other hand detailed #

Call for proposal

FP6-2003-AERO-1
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Coordinator

CENTRE DE RECHERCHE EN AERONAUTIQUE, ASBL
Address
Bâtiment Mermoz 1, 2ème Étage - Avenue Jean Mermoz, 30
Gosselies
Belgium

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Participants (10)

ASSOCIATION POUR LA RECHERCHE ET LE DÉVELOPPEMENT DES MÉTHODES ET PROCESSUS INDUSTRIELS
France
Address
Boulevard Saint-michel, 60
Paris

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CENTRE INTERNACIONAL DE METODES NUMERICS EN ENGINYERIA
Spain
Address
Edifici C1, Campus Nord Upc, C/ Gran Capità S/n
Barcelona

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EADS CCR
France
Address
37, Boulevard De Montmorency
Paris

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EUROPEAN AERONAUTIC DEFENCE AND SPACE COMPANY EADS FRANCE SAS
France
Address
37, Boulevard De Montmorency
Paris

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INSTITUT DE SOUDURE
France
Address
90 Rue Des Vanesses
Villepinte

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QUANTECH ATZ
Spain
Address
Edificio Nexus, Gran Capitan 2-4
Barcelona

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SAMTECH S.A.
Belgium
Address
Rue Des Chasseurs-ardennais 8
Angleur (Liège)

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SONACA S.A.
Belgium
Address
Route Nationale Cinq
Gosselies

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THE QUEEN'S UNIVERSITY OF BELFAST
United Kingdom
Address
University Road
Belfast

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UNIVERSITÉ CATHOLIQUE DE LOUVAIN
Belgium
Address
Place De L'université, 1
Louvain-la-neuve

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