Numerical simulation on end expansion of tubes fabricated through friction stir welding and validation of fracture behaviour

Sen, Debolina; Katiyar, Bhupesh Singh; Panda, Sushanta Kumar; Pal, Surjya K.

doi:10.1016/j.cirpj.2023.04.005

Cited by 4 publications

(1 citation statement)

References 32 publications

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“…Tubular components are used in body-in-white structure where post welding processes such as end expansion, bulging and so on are required which depends on the properties of the welded tubes. [35][36][37] Hence, evaluation of mechanical properties of the welded tube were performed and is shown in Figure 8. It was found that with increase in concavity of the tool, the thickness of the WZ decreased due to flash generation affecting the tensile properties of the welded tube.…”

Section: Mechanical Propertiesmentioning

confidence: 99%

Effect of tool concavity on flash formation during fabrication of tubes through friction stir welding

Sen

Pal

Panda

2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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Tubular components are challenging to weld using friction stir welding (FSW) process due to its curvature. In the present work, a novel strategy involving concave shoulder tool with three different concavities (3°, 6° and 9°) coupled with double pass was devised to fabricate longitudinal FSWed tubes of AA5083-O. An increase in concavity resulted in formation of flash and thinning of weld zone (WZ) due to excessive heat generation caused by enhanced tool contact with tube curvature. The flash generation led to the formation of porosity in the WZ. The tool with 6° concavity resulted in spherical pores whereas long and needle shaped pores were witnessed in case of 9° concave tool. However, negligible pores were observed with 3° concave tool leading to excellent WZ strength. Therefore, it was inferred that concave shoulder tool with small concavity along with double pass was suitable for welding tubes using FSW.

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Section: Mechanical Propertiesmentioning

confidence: 99%