Title Slide Subtitle © 2011 COMSOL. All rights reserved.

Background and Motivation Describe the technical application. What’s the motivation for modeling? What questions is the model supposed to answer? How are we going to model the application in COMSOL / What makes COMSOL especially suited to set up and simulate this application?

Geometry and Operating Conditions Show the model geometry and illustrate operating principles. Indicate modeling assumptions, for example, symmetry or infinite elements. Free flow in the heating tubes Symmetry reduces the model geometry Porous media flow in the catalytic bed

Modeling Interfaces Explain why an interface or a set of interfaces are used. Here you could show selections in the model wizard and selected equations that are solved for.

Model Setup If relevant, highlight features that facilitate model set up, for example, Multiphysics couplings or Material selections. If relevant, explain unique modeling techniques used in the example, for instance, global equations or integral constraints.

Results Answer the modeling questions from the Background and Motivation slide. Maintain width/height ratio when showing COMSOL GUI component and other graphics clips. If you want to include a movie, export as animated gif from COMSOL. Do not use graphics or scans from other sources than COMSOL. Place a shadow behind screenshots and other pictures to give them some definition. Use ‘Drop shadow Rectangle’ from the Picture Tools – Format menu.

Friction Stir Welding of Aluminum

Friction Stir Welding - Working principle Pore free weld joint No residual stresses due to shrinking Welding of dissimilar materials and plastics possible Joint to weld Rotating weld tool

Friction Stir Welding – Weld tool geometry Tool body generates friction heat on interface surfaces Central pin create deep weld joint

Friction Stir Welding – Heat transfer modeling General Heat Transfer Application Conduction, convection and radiation Convection cooling of surfaces: h-parameters Surface and central pin heat sources, q=f(Ff,r,  ) Material feed: ”convective velocity”

Friction Welding –Stationary result Temperature distribution, melting avoided! Feed rate optimization Cooling effects Feed rate: 1.6 mm/s Rotation speed: 640 rev/s Tool pressure: 25 kN/m2 T melt : 933 K