Numerical simulation of friction stir welding for aluminum alloy railway carriage manufacturing

High speed railway (HSR)uses aluminum hollow extrusions as new material and friction stir welding (FSW)is an innovative solid phase welding for such carriage manufacturing.Considering both the heat generation from tool shoulder friction and plastic deformation near the tool pin, a dual source finite element model of FSW is presented and a variety of weld joint designs are realized which satisfy the feature of FSW for the double skinned extrusion aluminum alloy structure.By ANSYS-APDL based re-exploitation, moving heat sources simulation is realized, and temperature field is obtained during the welding.The calculated results are in good agreernent with experimental data, which indicate the model's feasibility and accuracy.It will benefit the digestion &assimilation of domestic-made level HSR vehicle manufacturing technology and provide reference for FSW process parameters optimization.