Prediction of friction stir welding effects on AA2024-T3 plates and stiffened panels using a shell-based finite element model

Manufacturing-induced effects significantly affect in-service behaviour of welded structures, such as integrally stiffened panels for aeronautic applications. Being a complex phenomenon with several variables involved, the assessment of the effects coming from welding usually relies on numerical simulations. Here, a novel shell-based finite element model is proposed to accurately simulate the transient thermal fields and stress-strain distributions resulting from friction stir welding (FSW) processes. The capability of the model to predict (i) residual stresses, (ii) material softening and (iii) geometric distortion of the welded parts is assessed by the modelling and simulation of FSW applied on aluminium integrally stiffened panels.