Friction Stir Welding of 1Cr11Ni2W2MoV Martensitic Stainless Steel: Numerical Simulation Based on Coupled Eulerian Lagrangian Approach Supported with Experimental Work

Abstract

1Cr11Ni2W2MoV is a new martensitic heat-resistant stainless steel utilized in the manufacturing of aero-engine high-temperature bearing components. Welding of this type of steel using fusion welding techniques causes many defects. Friction stir welding (FSW) is a valuable alternative. However, few investigations have been performed on the FSW of steels because of the high melting point and the costly tools. Numerical simulation in this regard is a cost-effective solution for the FSW of this steel in order to optimize the parameters and to reduce the number of experiments for obtaining high-quality joints. In this study, a 3D thermo-mechanical finite element model based on the Coupled Eulerian Lagrangian (CEL) approach was developed to study the FSW of 1Cr11Ni2W2MoV steel. Numerical results of metallurgical zones’ shape and weld appearance at different tool rotation rates of 250, 350, 450 and 550 rpm are in good agreement with the experimental results. The results revealed that the peak temperature, plastic strain, surface roughness and flash size increased with an increase in the tool rotation rate. Lack-of-fill defect was produced at the highest tool rotation rate of 650 rpm. Moreover, an asymmetrical stir zone was produced at a high tool rotation rate.

Friction Stir Welding of 2205 Duplex Stainless Steel: Feasibility of Butt Joint Groove Filling in Comparison to Gas Tungsten Arc Welding

“…Tool materials for FSW of high softening temperature alloys must exhibit excellent properties at temperatures in excess of 900 °C [ 25 ]. There are various types of materials used in FSW of high softening temperature materials, such as WC-based materials [ 26 ], W–Re [ 27 ], and PCBN materials [ 28 ]. However, the FSW tool is subjected to severe stress and high temperatures, particularly for the welding of hard alloys such as steels and titanium alloys and the commercial application of FSW to these alloys is now limited by the high cost and short life of FSW tools [ 25 ].…”

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

“…With increasing distance from the shoulder, the strain rate in both materials decreased. This trend shows that at lower areas of the stir zone, stirring action decreases [72][73][74].…”

An investigation on mechanical and microstructural evolution of stationary shoulder friction stir welded aluminum alloy AA7075-T651

“…Top Surface Appearance of the SSFSWed AA7075-T6 joints Generally, it can be observed that the top surface of the joints is smooth with no semicircular rings that used to be observed with the rotating shoulder. 9,23,[25][26][27]43 This surface consists of two clear parts as can be seen clearly in Figure 5(a). The central part which represents the stirring zone by the rotation pin and this part is completely smooth without any surface roughness due to the high heat experienced.…”

“…[21][22][23] FSW of materials having low thermal conductivity, such as titanium alloys, is a challenge. 16,[24][25][26][27] One of the unique techniques used to meet this challenge and give the ability to weld different joint configurations is SSFSW. 28 The SSFSW technique was invented by TWI in 2004 and initially reported by Russel et al 28 to weld Ti-6Al-4V titanium alloy in the butt joint.…”