This paper is concerned with experiments and finite element (FE) simulations using the coupled Eulerian‒Lagrangian (CEL) method for multi-material joining by the flow drill screw (FDS) process. The FDS joining experiments involved various combinations of aluminum alloys (Al6061-T6 2.0t and Al6063-T6 2.0t), and steel (SPRC45E 1.6t) sheets. During the FDS joining, thermocouples and a thermal imaging camera, FLIR, were used to measure the elevated temperature near the joint. Cross-sections of the multi-material joint specimens were prepared to check the joining quality and the deformed shape of the materials. To consider the complexity of the joining process and convergence issue of numerical simulation, the FE modeling approach for the FDS joining was constructed based on the CEL method using the ABAQUS/Explicit, considering the strain rate and thermal softening dependent strain hardening of each material. From the comparison of experimental and FE simulation results, the reliability of the FE modeling was validated, revealing the predictability of the deformed shape was 90% or more, especially in terms of the bushing length. Furthermore, it was confirmed that the proposed modeling approach can accurately describe the temperature history and peak values during rapid joining.

本文涉及使用耦合欧拉-拉格朗日 (CEL) 方法通过热熔钻螺钉 (FDS) 工艺进行多材料连接的实验和有限元 (FE) 模拟。FDS 连接实验涉及铝合金（Al6061-T6 2.0t 和 Al6063-T6 2.0t）和钢（SPRC45E 1.6t）板材的各种组合。在 FDS 连接过程中，使用热电偶和热像仪 FLIR 来测量接头附近的高温。制备多材料接头样本的横截面以检查连接质量和材料的变形形状。为了考虑连接过程的复杂性和数值模拟的收敛问题，使用ABAQUS/Explicit基于CEL方法构建了FDS连接的有限元建模方法，考虑了每种材料的应变率和热软化相关的应变硬化。通过实验和有限元模拟结果的比较，验证了有限元建模的可靠性，显示变形形状的可预测性达到 90% 或更高，特别是在套管长度方面。此外，还证实所提出的建模方法可以准确描述快速连接过程中的温度历史和峰值。