Effects of tool tilt angle on the in-process heat transfer and mass transfer during friction stir welding

Zhang, Shuai; Shi, Qingyu; Liu, Qu; Xie, Ruishan; Zhang, Gong; Chen, Gaoqiang

doi:10.1016/j.ijheatmasstransfer.2018.04.067

Cited by 70 publications

(38 citation statements)

References 34 publications

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“…While the spatial distribution of heat flux for both the frictional heat generation and the plastic heat generation has been reported as near symmetric about the tool axis in many studies [45,46,54], other processing factors have been shown to influence the spatial distribution of the heat flux which is sensitive to the contact state at the tool/workpiece interface. Zhang et al [66] reported that, when the tilt angle is used in FSW, the contact between the welding tool and the workpiece could be incomplete, as shown in Fig. 2.…”

Section: Heat Generation and Temperaturementioning

confidence: 99%

“…2 Frictional force at the tool/workpiece interface. Reprinted from Zhang et al [66], Copyright (2018), with permission from Elsevier heat loss to the environment are the two dominant factors considering the analysis of the temperature. Compared with the heat generation in FSW, the heat loss to the environment has received less attention in the current thermo-mechanical analysis for FSW.…”

Section: Heat Generation and Temperaturementioning

confidence: 99%

See 1 more Smart Citation

Thermo-mechanical Analysis of Friction Stir Welding: A Review on Recent Advances

Chen

Zhang

Zhu

et al. 2019

Acta Metall. Sin. (Engl. Lett.)

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In recent studies, critical research interest exists in the thermo-mechanical analysis of the friction stir welding (FSW) process by numerical simulation. In this review, the thermo-mechanical analysis for FSW is overviewed regarding the computational approaches, the heat generation, the temperature, and the material flow behavior. Current concerns, challenges, and opportunities in current studies are discussed considering the application of the thermo-mechanical analysis. Generally, larger computational scale and better computational efficiency are required to allow better spatial resolution in future analysis. The concepts and approaches demonstrated in the thermo-mechanical analysis for FSW open up quantitative prospects for the design of the FSW process.

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Section: Heat Generation and Temperaturementioning

confidence: 99%

Section: Heat Generation and Temperaturementioning

confidence: 99%

Thermo-mechanical Analysis of Friction Stir Welding: A Review on Recent Advances

Chen

Zhang

Zhu

et al. 2019

Acta Metall. Sin. (Engl. Lett.)

Self Cite

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“…where T τ is the friction shear stress, This friction law in Equation (1) does not take into account the effect of the tilt angle. In case of having a tilt angle α (backwards), as the FSW tool advances in the weld direction, the contact surface that has a maximum friction value in front of the tool and minimum friction in the rear side rotates a certain angle β (counterclockwise) around the (counterclockwise) rotating axis due to the tilt influence [21]. This is detected from the experimental evidence in the reference [21] where the effect of tilting appears on the rotation of the contact print.…”

Section: Friction Model Including the Tilt Anglementioning

confidence: 99%

“…In previous works devoted to the numerical modeling of the effect of the tilt angle, this angle was considered in the geometrical setting, but not in the contact condition at the tool/work piece interface. Reference [21] is one of the few works, both experimental and numerical, to address heat and mass transfer due to the tilt angle. They use an Eulerian framework for an axisymmetric pin and an incomplete contact boundary condition that applies frictional tangential force on a contact area defined based on the tilt angle (α) and an in plane rotating angle (β) of the contact area.…”

Section: Introductionmentioning

confidence: 99%

“…The friction model is modified by introducing an in plane rotating angle (β) which depends on the tool tilt angle (α) and the advancing and rotating velocities. In the current study, this parameter is calibrated from the temperature field obtained experimentally for the tilt angle 2.5 • presented in reference [21]. Alternatively, the rotating angle β can be obtained experimentally from the relationship between the longitudinal and the transversal forces exerted on the tool.…”

Section: Introductionmentioning

confidence: 99%

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Effect of the Tool Tilt Angle on the Heat Generation and the Material Flow in Friction Stir Welding

Dialami

Cervera

Chiumenti

2018

Metals

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This work studies the effect of the tool tilt angle on the generated heat and the material flow in the work pieces joint by Friction Stir Welding (FSW). An apropos kinematic framework together with a two-stage speed-up strategy is adopted to simulate the FSW problem. The effect of tilt angle on the FSWelds is modeled through the contact condition by modifying an enhanced friction model. A rotated friction shear stress is proposed, the angle of rotation depending on the process parameters and the tilt angle. The proposed rotation angle is calibrated by the experimental data provided for a tilt angle 2.5°. The differences of generated heat and material flow for the cases of tool with tilt angle of 0° and 2.5° are discussed. It is concluded that due to the higher temperature, softer material and greater frictional force in the trailing side of the tool, the material flow in the rear side of the FSW tool with the title angle is considerably enhanced, which assists to prevent the generation of defect.

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A detailed process design for conventional friction stir welding of aluminum alloys and an overview of related knowledge

El-Moayed

Shash

Rabou

et al. 2020

Engineering Reports

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Friction stir welding (FSW) has matured considerably since its introduction in 1991. Over the last decades, it has indeed branched and been applied in different fields, such as automotive, aerospace, railway, and shipbuilding. This article aims to survey the basic knowledge related to the conventional FSW of aluminum alloys in order to provide a tool for understanding the friction stir processes. The review covers the five basic process parameters: rotational speed, welding speed, tool geometry, tilt angle, and plunge depth. Furthermore, it presents the related equations and recommended ranges of those parameters to facilitate the process design step for industrial implementation. A sample of 30 published articles was drawn for that purpose. The current article also discusses the main five properties most researchers are interested in, namely, microstructure, microhardness, tensile strength, residual stresses, and distortion.

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Effects of tool tilt angle on the in-process heat transfer and mass transfer during friction stir welding

Cited by 70 publications

References 34 publications

Thermo-mechanical Analysis of Friction Stir Welding: A Review on Recent Advances

Thermo-mechanical Analysis of Friction Stir Welding: A Review on Recent Advances

Effect of the Tool Tilt Angle on the Heat Generation and the Material Flow in Friction Stir Welding

A detailed process design for conventional friction stir welding of aluminum alloys and an overview of related knowledge

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