A numerical strategy to identify the FSW process optimal parameters of a butt-welded joint of quasi-pure copper plates: modeling and experimental validation

Iordache, Monica; Bădulescu, Claudiu; Diakhaté, Malick; Constantin, Marius Adrian; Niţu, Eduard; Demmouche, Younes; D’Hondt, Mathieu; Negrea, Denis

doi:10.1007/s00170-021-07296-9

Cited by 15 publications

(2 citation statements)

References 33 publications

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“…By tracking the material flow into and out of the computational/void domain using a 3D thermomechanical-based CEL approach, Bhattacharjee et al [64] projected surface, subsurface, and volumetric defects. Iordache et al [69] suggested a method based on the CEL approach for identifying the best parameters for a butt-welded joint of copper plates. They drastically cut the simulation duration by employing the mass scaling technique.…”

Section: Initial Statementioning

confidence: 99%

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A Review on Friction Stir Welding/Processing: Numerical Modeling

Akbari,

Asadi,

Sadowski

2023

Materials

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Friction stir welding (FSW) is a manufacturing process that many industries have adopted to join metals in a solid state, resulting in unique properties. However, studying aspects like temperature distribution, stress distribution, and material flow experimentally is challenging due to severe plastic deformation in the weld zone. Therefore, numerical methods are utilized to investigate these parameters and gain a better understanding of the FSW process. Numerical models are employed to simulate material flow, temperature distribution, and stress state during welding. This allows for the identification of potential defect-prone zones. This paper presents a comprehensive review of research activities and advancements in numerical analysis techniques specifically designed for friction stir welding, with a focus on their applicability to component manufacturing. The paper begins by examining various types of numerical methods and modeling techniques used in FSW analysis, including finite element analysis, computational fluid dynamics, and other simulation approaches. The advantages and limitations of each method are discussed, providing insights into their suitability for FSW simulations. Furthermore, the paper delves into the crucial variables that play a significant role in the numerical modeling of the FSW process.

show abstract

Section: Initial Statementioning

confidence: 99%

“…sub-surface, and volumetric defects. Iordache et al [69] suggested a method based on the CEL approach for identifying the best parameters for a butt-welded joint of copper plates. They drastically cut the simulation duration by employing the mass scaling technique.…”

Section: Initial Statementioning

confidence: 99%

A Review on Friction Stir Welding/Processing: Numerical Modeling

Akbari,

Asadi,

Sadowski

2023

Materials

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Process Parameters and Tool Design in Friction Stir Extrusion: A Sustainable Recycling Technique

Akbari,

Asadi,

Behnagh

et al. 2024

Engineering Reports

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Friction stir extrusion (FSE) is a versatile technique that plays a dual role in sustainable recycling and shaping of materials. This method involves a rotating mandrel and a fixed matrix within a mold, where compressed waste metal chips or primary bulk materials are introduced. The rotating mandrel exerts continuous axial pressure, generating frictional heat that softens and bonds the materials together. As the mandrel advances, the materials are reshaped and extruded through the cavity inside the mandrel or the space between the mandrel and the matrix, resulting in the desired product, such as wires or pipes. FSE finds applications in recycling machining wastes, improving powder metallurgy products, producing wire raw materials, creating structures with fine microstructures, and developing new alloys and composites. The resulting materials exhibit refined grains, leading to enhanced mechanical and metallurgical properties. This review article compiles experimental studies exploring the mechanical and microstructural characteristics of samples manufactured using FSE for recycling, reshaping, alloying, or bilayer production. Additionally, it discusses various tool, mold, and machine designs proposed by researchers. Beyond its unique properties, FSE is highlighted as an energy‐efficient, sustainable, and eco‐friendly process.

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Welding parameters optimization during plunging and dwelling phase of FSW 2219 aluminum alloy thick plate

Lü

Qiao

Qian

et al. 2022

Int J Adv Manuf Technol

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The in uence of welding parameters on temperature distribution in plunging and dwelling phase of friction stir welding (FSW) medium thickness 2219 aluminum alloy is blank. Improper selection of welding parameters will result in uneven temperature distribution along the thickness of the weldment, which will lead to welding defects and ultimately affect the mechanical properties of the weldment. To realize the prediction of temperature distribution and achieve the optimization of welding parameters, a simulation model of FSW 18mm thick 2219 aluminum alloy is built based on DEFORM. The validity of the simulation model is veri ed by temperature measurement experiments. With the minimum temperature difference in the core area of the weldment as target value, and weldable temperature range of 2219 aluminum alloy as constraint conditions, orthogonal experiments are conducted considering the rotational speed, the press amount, the tool tilt angle, the plunging traverse speed and the dwelling time.The results of variance analysis show that the rotational speed and the dwelling time are signi cant factors affecting temperature eld during plunging and dwelling phase. Through single factor simulation, the welding parameters in plunging and dwelling phase are optimized. This study provides a reference for realizing high-quality welding of a heavy rocket fuel tank.

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A numerical strategy to identify the FSW process optimal parameters of a butt-welded joint of quasi-pure copper plates: modeling and experimental validation

Cited by 15 publications

References 33 publications

A Review on Friction Stir Welding/Processing: Numerical Modeling

A Review on Friction Stir Welding/Processing: Numerical Modeling

Process Parameters and Tool Design in Friction Stir Extrusion: A Sustainable Recycling Technique

Welding parameters optimization during plunging and dwelling phase of FSW 2219 aluminum alloy thick plate

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