Investigating surface defect by tool-material interaction in friction stir welding using coupled Eulerian-Lagrangian approach

Das, Debtanay; Bag, Swarup; Pal, Sukhomay

doi:10.1016/j.mfglet.2021.10.003

Cited by 12 publications

(3 citation statements)

References 16 publications

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“…A recent investigation utilized a sequential simulation process to numerically evaluate residual stresses [83]. In the beginning, the temperature information was acquired from the CEL model and subsequently utilized in the mechanical model to examine the distribution of residual stress across the entire volume of the dissimilar workpiece.…”

Section: The Role Of the Residual Stressmentioning

confidence: 99%

A Review on Friction Stir Welding/Processing: Numerical Modeling

Akbari,

Asadi,

Sadowski

2023

Materials

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Friction stir welding (FSW) is a manufacturing process that many industries have adopted to join metals in a solid state, resulting in unique properties. However, studying aspects like temperature distribution, stress distribution, and material flow experimentally is challenging due to severe plastic deformation in the weld zone. Therefore, numerical methods are utilized to investigate these parameters and gain a better understanding of the FSW process. Numerical models are employed to simulate material flow, temperature distribution, and stress state during welding. This allows for the identification of potential defect-prone zones. This paper presents a comprehensive review of research activities and advancements in numerical analysis techniques specifically designed for friction stir welding, with a focus on their applicability to component manufacturing. The paper begins by examining various types of numerical methods and modeling techniques used in FSW analysis, including finite element analysis, computational fluid dynamics, and other simulation approaches. The advantages and limitations of each method are discussed, providing insights into their suitability for FSW simulations. Furthermore, the paper delves into the crucial variables that play a significant role in the numerical modeling of the FSW process.

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Section: The Role Of the Residual Stressmentioning

confidence: 99%

A Review on Friction Stir Welding/Processing: Numerical Modeling

Akbari,

Asadi,

Sadowski

2023

Materials

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“…Ajri et al [16] predicted the formation of cavities and tunnel defects. Surface tunnels or partial joints result from improper process parameters that can lead to insufficient heat generation and material mixing [17]. Excessive flash formation is another commonly occurring defect in FSW [18], which is generally observed on the retreating side (RS) due to the deposition of material behind the tool on the RS.…”

Section: Introductionmentioning

confidence: 99%

Material Defects in Friction Stir Welding through Thermo–Mechanical Simulation: Dissimilar Materials with Tool Wear Consideration

et al. 2022

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Despite the remarkable capabilities of friction stir welding (FSW) in joining dissimilar materials, the numerical simulation of FSW is predominantly limited to the joining of similar materials. The material mixing and defects’ prediction in FSW of dissimilar materials through numerical simulation have not been thoroughly studied. The role of progressive tool wear is another aspect of practical importance that has not received due consideration in numerical simulation. As such, we contribute to the body of knowledge with a numerical study of FSW of dissimilar materials in the context of defect prediction and tool wear. We numerically simulated material mixing and defects (surface and subsurface tunnel, exit hole, and flash formation) using a coupled Eulerian–Lagrangian approach. The model predictions are validated with the experimental results on FSW of the candidate pair AA6061 and AZ31B. The influence of tool wear on tool dimensions is experimentally investigated for several sets of tool rotations and traverse speeds and incorporated in the numerical simulation to predict the weld defects. The developed model successfully predicted subsurface tunnel defects, surface tunnels, excessive flash formations, and exit holes with a maximum deviation of 1.2 mm. The simulation revealed the substantial impact of the plate position, on either the advancing or retreating side, on the defect formation; for instance, when AZ31B was placed on the AS, the surface tunnel reached about 50% of the workpiece thickness. The numerical model successfully captured defect formation due to the wear-induced changes in tool dimensions, e.g., the pin length decreased up to 30% after welding at higher tool rotations and traverse speeds, leading to surface tunnel defects.

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“…A defect in a weld can cause material loss in the weld region and result in poor quality welds. The quality of the FSW weld depends on the selection of suitable process variables along with the appropriate interaction of the FSW tool and base metal [12].…”

Section: Introductionmentioning

confidence: 99%

Effects of different backing plates and tool design on the flash defect developed during friction stir welding of AA6061 aluminium alloy

Kulkarni

Pankade²

2022

Preprint

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The growing need for lightweight and higher strength materials, like aluminium alloys, in aircraft, ship construction, and railways has influenced manufacturers to adopt friction stir welding (FSW) due to the excellent mechanical properties of FSW joints as compared to other conventional welding processes. Friction stir welding (FSW) is defined by diverse interactions of thermal, mechanical, and tool geometry effects. The backing plate material is crucial for effective temperature control during the FSW process. Inappropriate FSW process parameters can result in flash defects. Due to extreme heat input, flash may be generated in FSW welds. This investigation aims to determine appropriate process parameters (backing plate thermal diffusivity, welding speed, and tool rotational speed) along with proper tool design to achieve flash defect-free joints. Visual observations indicate that the aluminium backing plate results in flash defect-free joints as compared to other backing plates.

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Investigating surface defect by tool-material interaction in friction stir welding using coupled Eulerian-Lagrangian approach

Cited by 12 publications

References 16 publications

A Review on Friction Stir Welding/Processing: Numerical Modeling

A Review on Friction Stir Welding/Processing: Numerical Modeling

Material Defects in Friction Stir Welding through Thermo–Mechanical Simulation: Dissimilar Materials with Tool Wear Consideration

Effects of different backing plates and tool design on the flash defect developed during friction stir welding of AA6061 aluminium alloy

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