Fully coupled thermomechanical simulation of friction stir welding of aluminum 6061-T6 alloy T-joint

Salloomi, Kareem N.

doi:10.1016/j.jmapro.2019.06.030

Cited by 68 publications

(24 citation statements)

References 22 publications

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“…e reason behind this assumption is the high complexity in getting precise thermal conductivity value for the gap that exists between AA 7075 plate and backing supporting plate, as described by Salloomi [24].…”

Section: Computational Modelmentioning

confidence: 99%

Temperature and Stress Evaluation during Three Different Phases of Friction Stir Welding of AA 7075-T651 Alloy

Salloomi

Hussein

Al-Sumaidae

2020

Modelling and Simulation in Engineering

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The current study performs an explicit nonlinear finite element simulation to predict temperature distribution and consequent stresses during the friction stir welding (FSW) of AA 7075-T651 alloy. The ABAQUS® finite element software was used to model and analyze the process steps that involve plunging, dwelling, and traverse stages. Techniques such as Arbitrary Lagrangian–Eulerian (ALE) formulation, adaptive meshing, and computational feature of mass scaling were utilized to simulate sequence events during the friction stir welding process. The contact between the welding tool and workpiece was modelled through applying Coulomb’s friction model with a nonlinear friction coefficient value. Also, the model considered the effect of nonlinear material properties as well as heat transfer conditions such as heat losses due to convection and thermal contact conductance between the workpiece and the backing plate interface on the thermal history. To validate the computational model results, an experimental procedure was carried out to measure temperature history on both sides of the specimen as well as the plunging force throughout the whole process time. The results obtained showed that symmetrical temperature distribution throughout the workpiece width was distinguished, implying that the tool rotation has a minor effect on the final temperature distribution. In addition, asymptotic V shape with high gradient temperature value in the weld nugget region after the full plunging was distinguished. Mechanical stresses and related plastic deformations generated, while achieving the FSW samples were evaluated in addition to the tool reaction force and heat generated to protect against tool failure.

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Section: Computational Modelmentioning

confidence: 99%

Temperature and Stress Evaluation during Three Different Phases of Friction Stir Welding of AA 7075-T651 Alloy

Salloomi

Hussein

Al-Sumaidae

2020

Modelling and Simulation in Engineering

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“…49,51,55,[62][63][64][65] A renowned source of material friction model data is the friction and wear experiments, specifically targeted at the alloy material. 34,37,44,66 While temperature-dependent friction coefficient for aluminium, titanium and steel alloys are readily available and simple to implement in computational modelling tools, 27,46,[67][68][69][70] this is not the situation for several nickel-based alloys. Most of the experimentally derived nickel-based alloy coefficient of friction data lack clear mathematical bases and often pose some challenges to implement in FEA studies.…”

Section: Introductionmentioning

confidence: 99%

Thermomechanical modelling for the linear friction welding process of Ni-based superalloy and verification

Okeke

Harrison

Tong

2020

Proceedings of the Institution of Mechanical Engineers, Part L:

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This paper presents a fully coupled thermomechanical model for the linear friction welding process of Inconel-718 nickel-based superalloy by using the finite element method. Friction heat, plastic work, and contact formulation were taken into account for two deformable plastic bodies oscillating relative to each other under large compressive force. The modelling results of the thermal history at the weldline interface and thermal field at a distance away from the rubbing surfaces were compared to instrumented data sourced from related publications for model verification. Optimal linear friction welding process parameters were identified via comparison of weld temperature to the liquidus temperature of Inconel-718 alloy. Comparison of interface temperature showed a consistent range of values above the solidus melting temperature (1250 ℃) and below the liquidus melting temperature (1360 ℃) of Inconel-718 alloy. For the first time, a visible linear friction welding process window is identified using a thermomechanical computational modelling method. Through computational modelling, the influence of welding process parameters on the heat transfer and deformation of weld was systematically investigated.

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“…where _ Q F is the frictional heat generation rate and _ Q P is the plastic heat generation rate. The frictional heat generation is the product of slip-rate and tangential stress at the interface, as expressed by equation (9). Moreover, the amount of material deformation determines the plastic deformation heat generation as described in equation 10_…”

Section: Contact Interactions and Boundary Conditionsmentioning

confidence: 99%

“…Another method that has been widely used to model FSW is ALE. 9 Akbari et al 10 modeled the friction stir processing (FSP) of A356 using the ALE method. They explained microstructural difference at advancing side (AS) and retreating side (RS) based on the simulation results for strain and temperature history.…”

Section: Introductionmentioning

confidence: 99%

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Dissimilar friction stir lap welding of aluminum to brass: Modeling of material mixing using coupled Eulerian–Lagrangian method with experimental verifications

Akbari

Asadi

2020

Proceedings of the Institution of Mechanical Engineers, Part L:

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The intermetallic compounds formation and inter-material mixing have a critical impact on achieving a sound joint with fine mechanical properties in the case of dissimilar metal friction stir welding. In this investigation formation of intermetallic compounds as well as material flow that results in inter-material mixing during friction stir lap welding of aluminum and brass are studied. First, the 2.5-mm-thick aluminum sheet was laid on the same-thickness brass sheet and then, friction stir lap welding was applied using a tool with 4-mm pin length and 6-mm pin diameter. Next, experimental investigations were performed using scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, microhardness, and tensile shear test to probe the chemical compositions and intermetallic formation in the stir zone. Moreover, the coupled Eulerian–Lagrangian method is employed to simulate the stir zone formation during the process to further study inter-material mixing. In this method, the workpiece is modeled using Eulerian formulation, while Lagrangian formulation is utilized to model the tool. The model successfully predicts the stir zone formation and inter-material mixing in the aluminum–brass interface. Results shows that by increasing tool rotational speed from 500 to 2000 r/min the amount of inter material mixing significantly increases. Therefore, to achieve a joint with the highest strength in friction stir lap welding of aluminum–brass, the rotational speed should be lowered as much as it can produce defect-free joint.

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Fully coupled thermomechanical simulation of friction stir welding of aluminum 6061-T6 alloy T-joint

Cited by 68 publications

References 22 publications

Temperature and Stress Evaluation during Three Different Phases of Friction Stir Welding of AA 7075-T651 Alloy

Temperature and Stress Evaluation during Three Different Phases of Friction Stir Welding of AA 7075-T651 Alloy

Thermomechanical modelling for the linear friction welding process of Ni-based superalloy and verification

Dissimilar friction stir lap welding of aluminum to brass: Modeling of material mixing using coupled Eulerian–Lagrangian method with experimental verifications

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