Computational Analysis of Material Flow During Friction Stir Welding of AA5059 Aluminum Alloys

Grujičić, M.; Arakere, G.; Pandurangan, B.; Ochterbeck, J. M.; Yen, Chian-Fong; Cheeseman, B. A.; Reynolds, Anthony P.; Sutton, Michael A.

doi:10.1007/s11665-011-0069-z

Cited by 67 publications

(24 citation statements)

References 22 publications

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“…Extending the original work of Zhang and coworkers [20,21], Grujicic and co-workers [14][15][22][23][24][25][26][27][28][29][30][31] advanced the FSW process modeling and its application to the welding of thick all-metal armor structures, so that the modeling can address the following critical issues: (a) the effect of various FSW process parameters (e.g. tool geometry and material, rotational and traverse speeds of the tool, tool tilt angle and plunge depth, thickness of the workpiece, contact pressure) on the material flow, microstructure evolution, residualstress development and defect formation within FSW joints; (b) establishment of the functional relationships between the material microstructure and defect content within different portions of the FSW joint and the local mechanical properties (e.g.…”

Section: Prior Computational Work On Dissimilar-materials Fswmentioning

confidence: 78%

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Computational analysis of inter-material mixing and weld-flaw formation during dissimilar-filler-metal friction stir welding (FSW)

Grujičić

Yavari

Ramaswami

et al. 2015

Multidiscipline Modeling in Materials and Structures

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Friction stir welding (FSW) butt-joining involving the use of a dissimilar filler-metal insert between the retreating and advancing portions of the workpiece is investigated computationally using a Combined Eulerian-Lagrangian (CEL) finite element analysis (FEA). The FEA employed is of a two-way thermo-mechanical character (i.e. frictional-sliding/plastic-work dissipation was taken to act as a heat source in the energy conservation equation), while temperature is allowed to affect mechanical aspects of the model through temperature-dependent material properties. Within the analysis, the workpiece and the filler-metal insert are treated as different materials within the Eulerian subdomain, while the tool was treated as a conventional Lagrangian sub-domain. The use of the CEL formulation within the workpiece insert helped avoid numerical difficulties associated with excessive Lagrangian element distortion. The emphasis of the computational analysis was placed on the understanding of the inter-material mixing and weld-flaw formation during a dissimilar-material FSW process. The results obtained revealed that, in order to obtain flaw-free FSW joints with properly mixed filler-and basematerials, process parameters including the location of the tool relative to the centerline of the weld must be selected judiciously.

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Section: Prior Computational Work On Dissimilar-materials Fswmentioning

confidence: 78%

“…Since details regarding the use of the conventional Lagrangian FEA in the FSW process simulation can be found in our prior work (e.g. [29][30][31]), only the features specific to the CEL analysis will be covered here.…”

Section: Computational Modeling and Analysismentioning

confidence: 99%

Computational analysis of inter-material mixing and weld-flaw formation during dissimilar-filler-metal friction stir welding (FSW)

Grujičić

Yavari

Ramaswami

et al. 2015

Multidiscipline Modeling in Materials and Structures

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“…The work piece is meshed using eight node coupled temperature displacement, brick elements (C3D8RT). The Johnson-Cook Johnson and Cook [14] equation (1) describes the flow stress as a product of the equivalent strain rate, temperature dependent terms and several parameters to adequate the real behavior of the materials.…”

Section: Model Descriptionmentioning

confidence: 99%

Numerical Investigation of the Plunge Stage in Friction Stir Welding Using Various Tool Pin Profiles

2016

Arimpie - 2016

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Abstract-Friction stir welding (FSW) is a solid state joining process which uses a rotating tool consisting of a shoulder and a pin/probe. The shoulder applies a downward pressure to the work piece surface, generates heat through the friction and leads to plasticization of materials in the vicinity of pin. During traverse the rotating tool mixes the adjacent material in the stir zone, creating a joint without fusion. A better understanding of the plunge phase is critical with the growing role of friction stir welding and also in understanding tool wear in friction stir welding (FSW) of high strength alloys. This paper investigates the plunge stage in friction stir welding using various tool pin profiles through numerical modeling. A 3D finite element-based model (FEM) of the plunge stage was developed using the commercial code ABAQUS to study the thermo mechanical processes involved during the plunge stage. The strain rate and temperature-dependent Johnson-Cook material law is adopted in the FEM.

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“…Extending the original work of Zhang et al (Ref 9,10), Grujicic et al (Ref 3,[11][12][13][14][15][16][17][18][19][20] advanced the FSW process modeling and its application to the welding of thick all-metal armor structures, so that the modeling can address the following critical issues:…”

Section: Prior Fsw Process-modeling Effortsmentioning

confidence: 99%

Prediction of the Grain-Microstructure Evolution Within a Friction Stir Welding (FSW) Joint via the Use of the Monte Carlo Simulation Method

Grujičić

Ramaswami

Snipes

et al. 2015

J. of Materi Eng and Perform

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A thermo-mechanical finite element analysis of the friction stir welding (FSW) process is carried out and the evolution of the material state (e.g., temperature, the extent of plastic deformation, etc.) monitored. Subsequently, the finite-element results are used as input to a Monte-Carlo simulation algorithm in order to predict the evolution of the grain microstructure within different weld zones, during the FSW process and the subsequent cooling of the material within the weld to room temperature. To help delineate different weld zones, (a) temperature and deformation fields during the welding process, and during the subsequent cooling, are monitored; and (b) competition between the grain growth (driven by the reduction in the total grain-boundary surface area) and dynamic-recrystallization grain refinement (driven by the replacement of highly deformed material with an effectively ''dislocation-free'' material) is simulated. The results obtained clearly revealed that different weld zones form as a result of different outcomes of the competition between the grain growth and grain refinement processes.

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Computational Analysis of Material Flow During Friction Stir Welding of AA5059 Aluminum Alloys

Cited by 67 publications

References 22 publications

Computational analysis of inter-material mixing and weld-flaw formation during dissimilar-filler-metal friction stir welding (FSW)

Computational analysis of inter-material mixing and weld-flaw formation during dissimilar-filler-metal friction stir welding (FSW)

Numerical Investigation of the Plunge Stage in Friction Stir Welding Using Various Tool Pin Profiles

Prediction of the Grain-Microstructure Evolution Within a Friction Stir Welding (FSW) Joint via the Use of the Monte Carlo Simulation Method

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