Coupled Eulerian–Lagrangian prediction of thermal and residual stress environments in dissimilar friction stir welding of aluminum alloys

Salloomi, Kareem N.; Al-Sumaidae, S.

doi:10.1016/j.jajp.2021.100052

Cited by 29 publications

(9 citation statements)

References 18 publications

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“…Also, the residual strains can be exacerbated by the heat produced while FSW [33]. The samples welded by the FSW technique normally have more residual stress on the retreating side and a lower value on the advancing side [13]. The microstructure of SZ shows minimal joint defects which may reduce the residual stress in the joints.…”

Section: Adequacy Of the Developed Modelmentioning

confidence: 99%

“…The residual stresses in the welding are measured experimentally by XRD, hole drilling method, the ultrasonic method, and the magnetic method [11,12]. The residual stress in dissimilar AA6061-T6 and AA2024-T3 alloys welded by FSW was studied through a Coupled Eulerian-Lagrangian (CEL) finite element simulation algorithm and resulted in an efficient approach [13]. Sonne et al [14] explored the slitting method to measure residual stress in the friction stir welded aluminum alloy 2024-T3 which concluded yield stress influenced residual stress.…”

Section: Introductionmentioning

confidence: 99%

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Investigating the Effect of Fsw Process Parameters on Microstructure, Residual Stress, Hardness and Tensile Strength of Welding Dissimilar Al Alloy

2022

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The aim of this research work was to study the influence of the Friction Stir Welding process parameters while welding dissimilar AA6066 and AA1060 alloys. The effects of parameters on responses to microstructure, residual stress, hardness, and tensile strength were investigated. The Response Surface Methodology (RSM)-Box Behnken design was employed to conduct the experiments. The regression model was developed from the measured data and the adequacy of the model was also verified using ANOVA. The microstructure analysis exhibited grains sizes in heat affected zone (HAZ) and stir zone (SZ). The LCR ultrasonic testing method was used to measure the residual stress in the stirred zone of the welded samples and the results showed that compressive residual stress was generated. The weld quality has improved by optimizing the parameters of tool design, rotational speed, and welding speed using the RSM technique. The validation test was conducted to verify the predicted model, the responses exhibited improvement in the hardness and tensile strength.

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Section: Adequacy Of the Developed Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Investigating the Effect of Fsw Process Parameters on Microstructure, Residual Stress, Hardness and Tensile Strength of Welding Dissimilar Al Alloy

2022

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“…Non-Newtonian viscosity was assumed to change with the temperature and strain rate [39]. For this reason, the viscosity of each BM (µ) as a function of flow stress and strain rate) can be defined [40][41][42]:…”

Section: Materials Modelmentioning

confidence: 99%

Effect of Pin Shape on Thermal History of Aluminum-Steel Friction Stir Welded Joint: Computational Fluid Dynamic Modeling and Validation

et al. 2021

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This article studied the effects of pin angle on heat generation and temperature distribution during friction stir welding (FSW) of AA1100 aluminum alloy and St-14 low carbon steel. A validated computational fluid dynamics (CFD) model was implemented to simulate the FSW process. Scanning electron microscopy (SEM) was employed in order to investigate internal materials’ flow. Simulation results revealed that the mechanical work on the joint line increased with the pin angle and larger stir zone forms. The simulation results show that in the angled pin tool, more than 26% of the total heat is produced by the pin. Meanwhile, in other cases, the total heat produced by the pin was near 15% of the total generated heat. The thermo-mechanical cycle in the steel zone increased, and consequently, mechanical interlock between base metals increased. The simulation output demonstrated that the frictional heat generation with a tool without a pin angle is higher than an angled pin. The calculation result also shows that the maximum heat was generated on the steel side.

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“…Additionally, the numerical outcomes were validated with experimental results. Kareem et al 17 performed a FE simulation to analyse thermal, residual stress and strain fields in dissimilar FSW of AA6061-T6 and AA2024-T3 alloys. The discussion related that longitudinal residual stress was dominant compared to transverse residual stress and observed to be greater on the AA6061-T6 region.…”

Section: Introductionmentioning

confidence: 99%

Experimental studies on friction stir welding of aluminium alloy 5083 and prediction of temperature distribution using arbitrary Lagrangian–Eulerian-based finite element method

Pramod

Jain

Kumar³

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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The present work focused on welding aluminium alloy 5083 using the friction stir welding process. Suitable welding process parameters were identified to fabricate a defect-free butt joint with a tool rotational speed of 1600 rpm, traverse speed of 20 mm/min and tilt angle of 3°. The microstructure at the nugget zone, thermo mechanically affected zone, heat-affected zone and base metal zone are examined. Mechanical properties of the weldment exhibited promising results with an average joint efficiency and hardness of 75.70% and 94.0 ± 5.0 vickers hardness, respectively. Fractography revealed ductile mode of failure in base and weld metal tensile samples. Furthermore, a 3D thermomechanical finite element model was utilized to simulate the friction stir welding process using the selected process parameters. Arbitrary Lagrangian–Eulerian-based model aided in predicting residual stress distributions and thermal history during the friction stir welding process.

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Coupled Eulerian–Lagrangian prediction of thermal and residual stress environments in dissimilar friction stir welding of aluminum alloys

Cited by 29 publications

References 18 publications

Investigating the Effect of Fsw Process Parameters on Microstructure, Residual Stress, Hardness and Tensile Strength of Welding Dissimilar Al Alloy

Investigating the Effect of Fsw Process Parameters on Microstructure, Residual Stress, Hardness and Tensile Strength of Welding Dissimilar Al Alloy

Effect of Pin Shape on Thermal History of Aluminum-Steel Friction Stir Welded Joint: Computational Fluid Dynamic Modeling and Validation

Experimental studies on friction stir welding of aluminium alloy 5083 and prediction of temperature distribution using arbitrary Lagrangian–Eulerian-based finite element method

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