Friction Stir Butt Welding of Commercially Pure Copper Plates

Friction Stir Welding (FSW) is a solid state joining process realized by the interaction between a non-consumable welding tool that rotates on the contact surfaces of the combined parts. Welding dissimilar materials aluminum and copper by FSW are of great interest because Al and Cu are two most common engineering materials widely used in many industries. This paper presents an investigation concerning the influence of the rotation of the tool on temperatures during the welding process. Also, the welding of copper and aluminum materials by FSW process was simulated using a finite element model. Three-dimensional FE model has been developed in ABAQUS/Explicit using the Coupled Eulerian Lagrangian method, the Johnson–Cook material law and the Coulomb’s Law of friction and was validated by infrared thermography method and thermocouple measurement.

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“…Thermal and mechanical parameters of AA 1200 and Cu 99 that were used in this analysis are shown in Table 2, were taken from references [10,11].…”

Section: Materials Modelmentioning

confidence: 99%

Evaluation of Thermal Distribution in Friction Stir Welding on Dissimilar Materials (Cu-Al) Using Infrared Thermography and Numerical Simulation

Iordache

Niţu

Bădulescu

et al. 2016

AMR

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“…Achieved from the experimental results that any increase in rotational speed at fixed value of traverse speed will cause an increase in the strength of the welding join. Gihad et al [8] utilized experimental and finite element analysis with pure copper as the material type. Constant value of rotational speed was employed in order to determine the quality of welding joint.…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Optimization of Friction Stir Welding Parameters

Jasim¹,

Saleh²,

Jasim³

2023

BJES

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In this paper friction stir welding process has been studied whereby utilized FEM method (Ansys software ver. 20). The main effective parameter in this process were rotational speed, linear speed, tool shoulder radius, heat transfer coefficient and clamping percentage to study their influence on represent temperature, von misses stress and frictional stress distribution. Because of the difficulty to obtained the number of the simulation cases in order to get the most important results, Taguchi L27 orthogonal array was apply to reduce the total number of the simulation cases. Pure copper (t = 3.18 mm) material type was applied as work plate material. ANOVA statistical tool was utilized to achieved the optimization process after the simulation cases done. Percentage of contribution of each parameter can be obtained by ANOVA table and mean of S/N ratio plot. Validation process was achieved between the Current study and experiment work in the temperature distribution field with percentage of error 2.7 %. From optimization result It is found that the optimum condition in order to obtained good results for temperature was rotational speed of (450 rpm), linear speed (2.75 mm/s), tool shoulder radius (7 mm), heat transfer coefficient (300 w/m2 K), clamping distance percentage (40 %). And for von misses stress was rotational speed of (550 rpm), linear speed (3 mm/s), tool shoulder radius (7 mm), heat transfer coefficient (300 w/m2 K), clamping distance percentage (20 %). While for frictional stress was rotational speed of (450 rpm), linear speed (2.5 mm/s), tool shoulder radius (7 mm), heat transfer coefficient (300 w/m2 K), clamping distance percentage (30 %).

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