A Review on Advancement in Friction Stir Welding Considering the Tool and Material Parameters

Mahakur, Vijay Kumar; Gouda, Krushna; Patowari, Promod Kumar; Bhowmik, Sumit

doi:10.1007/s13369-021-05524-8

Cited by 12 publications

(8 citation statements)

References 103 publications

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“…The material properties of the friction disc used in the simulation are: Coefficient of friction  = 0.3; Young's modulus E = 300 MPa; Poisson's ratio  = 0.25; Material density  = 1800 kg/m 3 ; Thermal expansion coefficient  = 1210 -6 1/K; Specific heat c = 1000 J/kgK; Thermal conductivity k = 0.65 W/mK. Moreover, the parameter controlling the fraction of heat going to the pin (Equation ( 9)), 𝜂, is set to 0.5, while the penalty coefficient is set to p = 110 6 . Furthermore, the pressure applied to the pin is p = 0.2 MPa, while the model parameters of the pin are the same as in the above simulations.…”

Section: Model Validation Against Experimental Results From a Pin-on-...mentioning

confidence: 99%

“…Frictional sliding induced heating effects cause concern in tribological applications, such as friction clutches and brakes [1,2], machining of metals [3,4,5], and friction stir welding [6]. Moreover, substantial local temperature rise may also occur in fretting contact [7], but the temperature effects seem to be seldom included in fretting analyses, see e.g.…”

Section: Introductionmentioning

confidence: 99%

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A thermo-mechanical numerical method for modelling heating due to frictional sliding

Saksala

2024

RakMek

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Heating due to frictional sliding is an important phenomenon in tribological applications. The present study develops a numerical method based on the finite elements (FE) for modelling frictional sliding induced heating. More specifically, the method is designed for applications where the behavior of the tool part of the frictional contact couple is not critical so that it can be idealized as a rigid body. The contact between the tool and the target, assuming linear elastic material, is modelled with the penalty method. The FE-discretized balance of linear momentum is time discretized with the Newmark scheme, and the FE-discretized heat equation is time discretized with the backward Euler scheme. The global coupled thermo-mechanical problem is solved with a globally iterative staggered approach. The frictional contact model is verified against analytical solution of a rotating blade pressed against a plane. Finally, a validation simulation of a pin-on-disc tribology test is carried out.

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Section: Model Validation Against Experimental Results From a Pin-on-...mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A thermo-mechanical numerical method for modelling heating due to frictional sliding

Saksala

2024

RakMek

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“…In this regard, the joining of steel to Al alloys is considered to be the most potential pair of alloys to use in the fabrication of structural, however, it is extremely challenging to weld them [2]. The particular alloy pair AA 5083 and HSLA steel is contextually important as they are of great interest for a variety of applications in the automobile, shipbuilding and railways industries [3,4].…”

Section: Introductionmentioning

confidence: 99%

A study on residual stress generation versus recrystallisation in FSW joint of dissimilar alloy pair of the AA5083 and HSLA steel

Sahu

Paul

Sinha

et al. 2023

Science and Technology of Welding and Joining

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The distribution of residual stresses across the joint interface of dissimilar joining between AA5083 and HSLA steel by friction stir welding technique was investigated through 2D XRD method and a numerical simulation model. The measured and simulated residual stress distributions are compared and discussed in the context of active recrystallisation mechanism and the possible presence of intermetallic compound (IMC) layers across the joint interface. The active dynamic recrystallisation (DRX) and multiple Fe/Al series IMCs as evident from the EBSD and 2D XRD, respectively critically demonstrated the variation in residual stresses between the experimental and theoretical values. The highest residual stress values of 375 and 281 MPa were recorded for the HSLA steel side and AA5083 side, respectively.

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“…When a thread is used on the pin, the aluminium moves downward, depending on the pin's rotational direction. The soft polymer facilitates penetration at the intersection of the specimens [10,11]. The aluminium anchor is located in the thermo-mechanically affected zone (TMAZ).…”

Section: Introductionmentioning

confidence: 99%

A Study of the Friction Stir Lap Welding of AA5052 and Polypropylene

Alhatti,

Sheikh-Ahmad,

Almaskari

et al. 2023

Polymers

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Friction stir lap welding (FSLW) remains a pioneering technique for creating hybrid joints between AA5052 aluminium alloy and polypropylene (PP), particularly with the metal-on-top configuration. Building upon previous research, this study introduces a tapered fluted pin tool design and investigates its effectiveness in the welding process. Our results, supported by ANOVA, chemical, and microstructural analyses, reiterate that the optimal welding parameters stand at a rotational speed of 1400 RPM and a traverse speed of 20 mm/min. This combination produces a joint tensile strength of 3.8 MPa, signifying 16.54% of the weaker material’s inherent strength. Microstructural evaluations revealed a unique composite of aluminium chips intermeshed with PP, strengthened further by aluminium hooks. Crucially, mechanical interlocking plays a predominant role over chemical bonding in achieving this joint strength. The study underscores the absence of significant C-O-Al bonds, hinting at the PP degradation without the thermo-oxidation process. Additionally, joint strength was found to inversely correlate with the interaction layer’s thickness. The findings fortify the promise of FSLW with the novel fluted pin design for enhancing joints between AA5052 and PP, emphasising the potential of mechanical interlocking as a principal factor in achieving high-quality welds.

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A Review on Advancement in Friction Stir Welding Considering the Tool and Material Parameters

Cited by 12 publications

References 103 publications

A thermo-mechanical numerical method for modelling heating due to frictional sliding

A thermo-mechanical numerical method for modelling heating due to frictional sliding

A study on residual stress generation versus recrystallisation in FSW joint of dissimilar alloy pair of the AA5083 and HSLA steel

A Study of the Friction Stir Lap Welding of AA5052 and Polypropylene

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