Numerical simulation and experimental investigation on friction stir welding of 6061-T6 aluminum alloy

Zhang, Jingqing; Shen, Yifu; Li, Bo; Xu, Haisheng; Yao, Xiyu; Kuang, Binbin; Gao, Jicheng

doi:10.1016/j.matdes.2014.03.043

Cited by 80 publications

(27 citation statements)

References 24 publications

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“…The use of the information on the material flow path and the material velocity at the workpiece is one of the major information for analyzing the defect formation. Zhang et al [93] demonstrated a defect-prone region based on the predicted three-dimensional material flow field and the experimental microstructure. A similar concept was also indicated in the experimental work Fig.…”

Section: Materials Flow Behaviormentioning

confidence: 99%

Thermo-mechanical Analysis of Friction Stir Welding: A Review on Recent Advances

Chen

Zhang

Zhu

et al. 2019

Acta Metall. Sin. (Engl. Lett.)

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In recent studies, critical research interest exists in the thermo-mechanical analysis of the friction stir welding (FSW) process by numerical simulation. In this review, the thermo-mechanical analysis for FSW is overviewed regarding the computational approaches, the heat generation, the temperature, and the material flow behavior. Current concerns, challenges, and opportunities in current studies are discussed considering the application of the thermo-mechanical analysis. Generally, larger computational scale and better computational efficiency are required to allow better spatial resolution in future analysis. The concepts and approaches demonstrated in the thermo-mechanical analysis for FSW open up quantitative prospects for the design of the FSW process.

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Section: Materials Flow Behaviormentioning

confidence: 99%

Thermo-mechanical Analysis of Friction Stir Welding: A Review on Recent Advances

Chen

Zhang

Zhu

et al. 2019

Acta Metall. Sin. (Engl. Lett.)

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“…T 0 is the ambient temperature, which is assumed to be 300 K in this study, k is the thermal conductivity of weld materials. 15) The boundary conditions at the bottom of the workpiece are formulated as:…”

Section: ð3þmentioning

confidence: 99%

Simulation and Experimental Study on Temperature and Flow Field in Friction Stir Welding of TC4 Titanium Alloy Process

Shen

et al. 2020

Mater. Trans.

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In this study, numerical simulation method was used to investigate the temperature field and the flow field of FSW for TC4 titanium alloy. According to the contact condition between the tool surface and the weld piece, a scientific heat source calculation method was built and its reliability has been verified by experiments. The temperature distribution characteristics of welding zone were investigated. The simulation results shows that the welding materials around the friction head flows like funnel-shape in a whole, similar to the shape of the friction head. The flow condition of welding materials is asymmetric with respect to the weld line, and the flow velocity increases with the greater distance from the center of the weld. As the depth of the weld increases, the flow capacity of the material gradually becomes weaker.

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“…When the frictional heat generation and the plastic deformation heat generation enter a stable state, the thin layer of the viscous fluid material around the FSW tool reaches a stable thickness and the welding enters a stable state. In the stable welding stage, due to the rotation and movement of the FSW tool, the front edge viscous fluid material fills the cavity created in the rear of the welding direction, forming a tight weld under the action of forging force [23,24].…”

Section: Finite Element Model Of Fswmentioning

confidence: 99%

Welding Characteristics Analysis and Application on Spacecraft of Friction Stir Welded 2A14-T6 Aluminum Alloy

Luo

Tang

et al. 2019

Materials

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According to the actual size parameters, the finite element model (FEM) of friction stir welding (FSW) was established, and the FEM was updated by experiments. The FSW of the 2A14-T6 high-strength aluminum alloy was simulated under a reasonable welding process parameter range, and the welding process parameters with good simulation effect were determined. The test was carried out under the same parameters, and the axial force of the FSW tool and temperature of the workpiece measuring point were collected. The comparison between the simulated data and the experimental data is reasonable, indicating the correctness of the FEM. The microstructure analysis of the welded joint shows that the grain size in the upper part of the weld nugget was smaller than that in the middle and lower parts, and there are obvious boundaries of grain size in each region of the joint. The hardness of the joint in the upper layer is higher than that in the middle and lower layers, and the minimum Vickers hardness value of the joint appears near the interface between the thermo-mechanically affected zone and the heat-affected zone on both sides of the weld. Tensile testing shows that the strength coefficient of the joint reaches 82.5% under this process parameter, and the sample breaks at the intersection of the material flow during stretching. After analyzing the final mechanical properties of the joint, we found that a degree of aerospace application can be achieved. Under this parameter, the welding test was carried out on the top cover of the rocket fuel tank. Firstly, melon valve welding, which is relatively difficult in welding conditions, was carried out, and a high-quality joint with good surface and no defects was obtained.

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Numerical simulation and experimental investigation on friction stir welding of 6061-T6 aluminum alloy

Cited by 80 publications

References 24 publications

Thermo-mechanical Analysis of Friction Stir Welding: A Review on Recent Advances

Thermo-mechanical Analysis of Friction Stir Welding: A Review on Recent Advances

Simulation and Experimental Study on Temperature and Flow Field in Friction Stir Welding of TC4 Titanium Alloy Process

Welding Characteristics Analysis and Application on Spacecraft of Friction Stir Welded 2A14-T6 Aluminum Alloy

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