Material flow in butt friction stir welds in AA2024-T3

Schmidt, Henrik; Dickerson, Terry; Hattel, Jesper Henri

doi:10.1016/j.actamat.2005.10.052

Cited by 320 publications

(161 citation statements)

References 3 publications

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“…The flow is deflected at the retreating side in the direction of rotation. Previous experimental work by Schmidt et al [37] carried out on aluminium showed the same results of material flow, where marker foils of copper flowed around the tool, broken into pieces then reverted around the retreating side in the same direction of rotation. Morisada et al [38] used a W tracer with the aid of an XR transmission system to monitor the material flow during FSW of aluminium Al050 and low carbon steel.…”

Section: Parent Materials Flow Around the Toolsupporting

confidence: 65%

Modelling of friction stir welding of DH36 steel

Al-moussawi

Smith

Young

et al. 2017

Int J Adv Manuf Technol

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A 3-D computational fluid dynamics (CFD) model was developed to simulate the friction stir welding of 6-mm plates of DH36 steel in an Eulerian steady-state framework. The viscosity of steel plate was represented as a nonNewtonian fluid using a flow stress function. The PCBN-WRe hybrid tool was modelled in a fully sticking condition with the cooling system effectively represented as a negative heat flux. The model predicted the temperature distribution in the stirred zone (SZ) for six welding speeds including low, intermediate and high welding speeds. The results showed higher asymmetry in temperature for high welding speeds. Thermocouple data for the high welding speed sample showed good agreement with the CFD model result. The CFD model results were also validated and compared against previous work carried out on the same steel grade. The CFD model also predicted defects such as wormholes and voids which occurred mainly on the advancing side and are originated due to the local pressure distribution between the advancing and retreating sides. These defects were found to be mainly coming from the lack in material flow which resulted from a stagnant zone formation especially at high traverse speeds. Shear stress on the tool surface was found to increase with increasing tool traverse speed. To produce a "sound" weld, the model showed that the welding speed should remain between 100 and 350 mm/min. Moreover, to prevent local melting, the maximum tool's rotational speed should not exceed 550 RPM.

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Section: Parent Materials Flow Around the Toolsupporting

confidence: 65%

Modelling of friction stir welding of DH36 steel

Al-moussawi

Smith

Young

et al. 2017

Int J Adv Manuf Technol

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“…There is no standard generally applicable rule for choosing the size and shape of the tool. A collection of typical tool geometries, in the literature [11][12][13][14][15], used for aluminium alloy is shown in Table 1. In these papers, the pin height, which varies from 1.5 mm to 7.9 mm, depends on the required weld depth.…”

Section: Fe Modelmentioning

confidence: 99%

“…Moataz et al [14] found that FSW process parameters such as feed rate and rotational speed had an appreciable effect on abnormal gain growth and tensile properties. In Schmidt et al [15] the material flow in FSW was investigated by various metallography techniques and computer tomography. It was stated in the paper that it was the first attempt in the literature to estimate flow velocities experimentally.…”

Section: Introductionmentioning

confidence: 99%

Parametric finite-element studies on the effect of tool shape in friction stir welding

Mackenzie

Hamilton

2010

Proceedings of the Institution of Mechanical Engineers, Part B:

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This version is available at https://strathprints.strath.ac.uk/27456/ Strathprints is designed to allow users to access the research output of the University of Strathclyde. Unless otherwise explicitly stated on the manuscript, Copyright © and Moral Rights for the papers on this site are retained by the individual authors and/or other copyright owners. Please check the manuscript for details of any other licences that may have been applied. You may not engage in further distribution of the material for any profitmaking activities or any commercial gain. You may freely distribute both the url (https://strathprints.strath.ac.uk/) and the content of this paper for research or private study, educational, or not-for-profit purposes without prior permission or charge.Any correspondence concerning this service should be sent to the AbstractThe success of the Friction Stir Welding (FSW) process, and the weld quality produced, depends significantly on the design of the welding tool. In this paper the effect of variation in various tool geometry parameters on FSW process outcomes, during the plunge stage, were investigated. Specifically the tool shoulder surface angle and the ratio of the shoulder radius to pin radius on tool reaction force, tool torque, heat generation, temperature distribution and size of the weld zone were investigated. The studies were carried out numerically using the finite element method. The welding process used AA2024 aluminium alloy plates with a thickness of 3 mm. It was found that, in plunge stage, the larger the pin radius the higher force and torque the tool experiences and the greater heat generated. It is also found that the shoulder angle has very little effect on energy dissipation as well as little effect on temperature distribution. Tables Table 1 Typical List of Figures

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“…When tool head turn to the A-side, tool traveling direction is mismatch tool rotational direction. This mismatch makes negative effect on material flow and fracturing Lazy-S. [11][12][13] It is encouraged to turn to same direction as tool rotational direction when welding direction change. The strength deteriorates at the specimen with continuous Lazy-S as Fig.…”

Section: Nonlinear Fsw Butt Joints (L-shape Butt Joints)mentioning

confidence: 99%

Optimization of Welding Condition for Nonlinear Friction Stir Welding

Takahara

Tsujikawa

Chung³

et al. 2008

Mater. Trans.

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The influence of nonlinear friction stir welding (FSW) tool control on joint properties was investigated. Although FSW is widely applied to linear joints, it is impossible for five-axis FSW machines to maintain all FSW parameters in optimum conditions during nonlinear welding. Nonlinear FSW joints should be produced according to an order of priority for FSW parameters. Tensile test results of butt joints with rectangular change in the welding direction on the plate plane (L-shape butt joints) change with various welding parameters. Results show that a turn to the retreating side is encouraged when the welding direction changes. The method of zero inclination tool angles is effective for nonlinear and plane welding.

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Material flow in butt friction stir welds in AA2024-T3

Cited by 320 publications

References 3 publications

Modelling of friction stir welding of DH36 steel

Modelling of friction stir welding of DH36 steel

Parametric finite-element studies on the effect of tool shape in friction stir welding

Optimization of Welding Condition for Nonlinear Friction Stir Welding

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