Modelling of the residual state of friction stir welded plates

Bastier, Arnaud; Maitournam, M.H.; Roger, F.; Van, K. Dang

doi:10.1016/j.jmatprotec.2007.10.083

Cited by 81 publications

(45 citation statements)

References 17 publications

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“…The interest of such numerical models to simulate FSW processing is clear and has been demonstrated by many literature works. Numerical simulations have been widely used to obtain temperature and mechanical fields (Schmidt and Hattel, 2005;Zhang and Zhang, 2008;Bastier et al, 2008;Fourment and Guerdoux, 2008). They provide a better understanding of the flow and heating mechanisms of FSW depending on the tool profiles, rotation speed, velocity speed, axial force (Colegrove and Shercliff, 2006;Zhang and Zhang, 2009b) in order to optimize the FSW process.…”

Section: Introductionmentioning

confidence: 99%

Understanding the material flow path of friction stir welding process using unthreaded tools

Lorrain

Favier

Zahrouni

et al. 2010

Journal of Materials Processing Technology

175

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a b s t r a c tMaterial flow during friction stir welding is very complex and not fully understood. Most of studies in literature used threaded pins since most industrial applications currently use threaded pins. However, initially threaded tools may become unthreaded because of the tool wear when used for high melting point alloys or reinforced aluminium alloys. In this study, FSW experiments were performed using two different pin profiles. Both pins are unthreaded but have or do not have flat faces. The primary goal is to analyse the flow when unthreaded pins are used to weld thin plates. Cross-sections and longitudinal sections of welds were observed with and without the use of material marker (MM) to investigate the material flow. Material flow with unthreaded pin was found to have the same features as material flow using classical threaded pins: material is deposited in the advancing side (AS) in the upper part of the weld and in the retreating side (RS) in the lower part of the weld; a rotating layer appears around the tool. However, the analysis revealed a too low vertical motion towards the bottom of the weld, attributed to the lack of threads. The product of the plunge force and the rotational speed was found to affect the size of the shoulder dominated zone. This effect is reduced using the cylindrical tapered pin with flats.

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Section: Introductionmentioning

confidence: 99%

Understanding the material flow path of friction stir welding process using unthreaded tools

Lorrain

Favier

Zahrouni

et al. 2010

Journal of Materials Processing Technology

175

View full text Add to dashboard Cite

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“…Rajesh et al [10] have investigated the residual stress distribution in the stir zone, heat-affected zone, and the base metal of AA6061using an analytical model. Bastier et al [11] have studied the residual stress of friction stir welded AA7050 plates using a steady-state thermomechanical model.…”

Section: Introductionmentioning

confidence: 99%

Experimental and theoretical evaluations of thermal histories and residual stresses in dissimilar friction stir welding of AA5086-AA6061

Aval

Serajzadeh

Kokabi

2011

Int J Adv Manuf Technol

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In this work, the thermomechanical responses during the dissimilar friction stir welding of aluminum alloys have been evaluated employing a three-dimensional model and the finite element software ABAQUS. Furthermore, welding experiments have been conducted under different working conditions and the temperature variations during and after welding as well as the produced residual stresses in various positions of the welded samples were measured using hole-drilling technique. The model results were then examined by experimental data, and a reasonable agreement was observed. It is found that tool rotational speed significantly affects the amount of maximum tensile residual stress while traverse speed mainly changes the distribution of transverse residual stresses. Also, both experimental and simulated results indicate that welding fixtures significantly affect the residual stress profiles as well as their magnitudes.

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“…The straightforward two-step strategy to compute the residual stresses is to transfer the temperature field obtained at nodes of the local model to the global one [16][17][18]. In this case, two possibilities exist.…”

Section: Solution Strategymentioning

confidence: 99%

“…The map of the residual stress was extrapolated from the numerical model along several directions by considering thermal actions only. A steady-state simulation of FSW was carried out by Bastier et al [17]. The simulation included two main steps.…”

mentioning

confidence: 99%

Local–global strategy for the prediction of residual stresses in FSW processes

Dialami

Cervera

Chiumenti

et al. 2016

Int J Adv Manuf Technol

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The final publication is available at Springer via http://dx.doi.org/10.1007/s00170-016-9016-3This work describes the local–global strategy proposed for the computation of residual stresses in friction stir welding (FSW) processes. A coupling strategy between the analysis of the process zone nearby the pin tool (local level analysis) and the simulation carried out for the entire structure to be welded (global level analysis) is implemented to accurately predict the temperature histories and, thereby, the residual stresses in FSW. As a first step, the local problem solves the material stirring as well as the heat generation induced by the pin and shoulder rotation at the heat affected zone. The Arbitrary Lagrangian Eulerian (ALE) formulation is adopted to deal with the rotation of complex pin shapes. A thermo-rigid-viscoplastic constitutive law is employed to characterize the viscous flow of the material, driven by the high-strain rates induced by the FSW process. A mixed temperature–velocity–pressure finite element technology is used to deal with the isochoric nature of the strains. The output of this local analysis is the heat generated either by plastic dissipation or by friction, and it is used as the power input for the welding analysis at structural (global) level. The global problem is tackled within the Lagrangian framework together with a thermo-elasto-viscoplastic constitutive model. In addition, in this case, the mixed temperature–displacement–pressure format is introduced to deal with the deviatoric nature of the plastic strains. The outcomes of this analysis are the distortions and the residual stresses after welding. The material used in this work is stainless steel 304 L; however, the methodology presented is applicable to a wide range of materials. The proposed numerical strategy is validated by the experimental evidence.Peer ReviewedPostprint (author's final draft

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Modelling of the residual state of friction stir welded plates

Cited by 81 publications

References 17 publications

Understanding the material flow path of friction stir welding process using unthreaded tools

Understanding the material flow path of friction stir welding process using unthreaded tools

Experimental and theoretical evaluations of thermal histories and residual stresses in dissimilar friction stir welding of AA5086-AA6061

Local–global strategy for the prediction of residual stresses in FSW processes

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