“…The reduced integration scheme was applied to decrease the computational time while preserving an acceptable level of accuracy. 15 Figure 5.Meshed model.…”
Section: Methodsmentioning
confidence: 99%
“…The reduced integration scheme was applied to decrease the computational time while preserving an acceptable level of accuracy. 15 Mass scaling. The CEL formulation facilitates the modeling of processes with large plastic deformations.…”
In the present research, a coupled Eulerian–Lagrangian model is developed to predict the forces and defects produced from AA6063 friction stir welding process. Furthermore, the obtained results from the developed model were validated experimentally by performing the welding process at different rotational and welding speed values. The results revealed an appearance of tunnel defect at all welded joints with surface flash. The current model successfully predicted both defects’ evolution. Additionally, it also generated force measurements comparable to those obtained experimentally. In addition, the developed Coupled Eulerian–Lagrangian model successfully predicted the generated force and the defects during friction stir welding process with maximum error of 14% and 18%. However, it failed in predicting the tunnel positions. In terms of the tensile strength, the largest tensile strength value was at 1250rpm and 50 mm/min, whereas the lowest one was at 1000 rpm and 25 mm/min. Moreover, the fracture locations were at the advancing side of all the welded joints.
“…The reduced integration scheme was applied to decrease the computational time while preserving an acceptable level of accuracy. 15 Figure 5.Meshed model.…”
Section: Methodsmentioning
confidence: 99%
“…The reduced integration scheme was applied to decrease the computational time while preserving an acceptable level of accuracy. 15 Mass scaling. The CEL formulation facilitates the modeling of processes with large plastic deformations.…”
In the present research, a coupled Eulerian–Lagrangian model is developed to predict the forces and defects produced from AA6063 friction stir welding process. Furthermore, the obtained results from the developed model were validated experimentally by performing the welding process at different rotational and welding speed values. The results revealed an appearance of tunnel defect at all welded joints with surface flash. The current model successfully predicted both defects’ evolution. Additionally, it also generated force measurements comparable to those obtained experimentally. In addition, the developed Coupled Eulerian–Lagrangian model successfully predicted the generated force and the defects during friction stir welding process with maximum error of 14% and 18%. However, it failed in predicting the tunnel positions. In terms of the tensile strength, the largest tensile strength value was at 1250rpm and 50 mm/min, whereas the lowest one was at 1000 rpm and 25 mm/min. Moreover, the fracture locations were at the advancing side of all the welded joints.
“…Therefore, the timing is perfect for taking the HYB process technology to the next level by developing a verified quantitative understanding of the different physical phenomena involved contributing to its unique multi-material joining capabilities. This will be done by taking full advantage of the previous modelling work mainly done on FSW of corresponding monometallic Al-Al butt welds [17][18][19] and condense all that accumulated knowledge into a finite element (FE)-based simulation model for HYB Al-steel butt welding. The HYB process model, which is built around the numerical code WELDSIM [20,21], will then be validated by comparison with in-situ thermocouple measurements and experimental hardness profiles.…”
In the present investigation, the numerical code WELDSIM is used to simulate butt welding of 4 mm thick plates of S355 steel and AA6082-T6 by Hybrid Metal Extrusion and Bonding (HYB). This is a new solid state joining process using continuous extrusion as a technique to enable aluminium filler metal additions. In WELDSIM, the finite element heat flow model is coupled to a frictional heating model, an isokinetic diffusion model for the interfacial intermetallic compound (IMC) formation and a nanostructure model for simulating reversion and re-precipitation of hardening phases inside the aluminium part of the joints during welding and subsequent natural ageing. The HYB process model is validated by comparison with experimental data obtained from in-situ thermocouple measurements and hardness testing carried out on three different Al-steel butt welds. Furthermore, scanning electron microscope examinations of the Al-steel interfaces have been conducted to check the predicted power of the IMC diffusion model. It is concluded that the process model is sufficiently relevant and comprehensive to be used in simulations of both the thermal, microstructure, and strength evolutions fields in these dissimilar butt welds. Some practical applications of the process model are described toward the end of the article, where particularly its potential for optimising the load-bearing capacity of the joints, is highlighted.
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