Residual stress in friction stir-welded Al sheets

Staron, Peter; Koçak, M.; Williams, Stewart; Wescott, Andrew

doi:10.1016/j.physb.2004.03.128

Cited by 147 publications

(91 citation statements)

References 7 publications

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“…Depending on the longitudinal tensioning load used, GMT can greatly reduce residual stresses at the weld line, or even introduce compressive stresses in this region [145,146,147,148], see Figure 15b. For welds in 2000-series aluminium alloy, the magnitude of tensioning stress that must be applied during welding to reduce the longitudinal residual stress to approximately zero, has been reported as 25-40% of the room temperature yield stress of the parent material [146,148].…”

Section: Global Mechanical Tensioningmentioning

confidence: 99%

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Contemporary approaches to reducing weld induced residual stress

Coules

2013

Materials Science and Technology

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General rightsThis document is made available in accordance with publisher policies. Please cite only the published version using the reference above. AbstractSelf-equilibrating residual stresses may occur in materials in the absence of external loading due to internal strain inhomogeneity. While favourable distributions of residual stress can bestow an object with the appearance of superior material properties, most welding processes leave behind residual stresses in particularly unfavourable patterns, causing a greater susceptibility to fracture-based failure mechanisms and unintended deformation. Currently, heat treatment is the primary means of removing these stresses, but since the formation of residual stress is dependent upon many material and process factors, there are several other viable mechanisms (using thermal, mechanical or phase transformation effects) by which it may be modified. It is only now, using relevant advances in numerical and experimental methods, that these techniques are being fully explored. This article gives a brief introduction to weld-induced residual stresses and reviews the current state-of-the-art with regard to their reduction. Emphasis is placed on the recent development of unconventional techniques, and the mechanisms by which they act.

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Section: Global Mechanical Tensioningmentioning

confidence: 99%

“…Additionally, since the force needs to be applied in the same direction as the weld line, application to complex welds would be very difficult. Consequently, the applicability of GMT to practical industrial processes has not yet been demonstrated [145].…”

Section: Global Mechanical Tensioningmentioning

confidence: 99%

Contemporary approaches to reducing weld induced residual stress

Coules

2013

Materials Science and Technology

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“…Although FSW alleviates many metal lurgical problems found with fusion welding, such as liquation and solidification cracking, friction stir welds still suffer from similar levels of residual stress, resulting from the weld's local thermal field [2]. High residual stresses are undesirable due to induced distortion and their effect on mechanical performance.…”

Section: Introductionmentioning

confidence: 99%

FE Modelling of Mechanical Tensioning for Controlling Residual Stresses in Friction Stir Welds

Richards

Prangnell

Withers

et al. 2007

MSF

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SYNOPSISAlthough Friction Stir Welding (FSW) avoids many of the problems encountered when fusion welding high strength Al-alloys, it can still result in substantial residual stresses that have a detrimental impact on service life and induce distortion. An FE model has been developed to investigate the effectives of the mechanical tensioning technique for controlling residual stresses in FSWs. The model purely considered the heat input and the mechanical effects of the tool were ignored. Variables, such as tensioning level, heat input, and plate geometry, have been studied. Good general agreement was found between modelling results and residual stress measurements, justifying the assumption that the stress development is dominated by the thermal field. The results showed a progressive decrease in the residual stresses for increasing tensioning levels and, although affected by the heat input, a relatively low sensitivity to the welding variables. At tensioning levels greater than ~ 50% of the room temperature yield stress, tensile stresses were replaced by compressive residual stresses within the weld. Subsequently the modelling has been used to examine how mechanical tensioning can be applied in practical applications.

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“…The residual stress distributions of friction stir welds have been studied by experiments reported in [Dalle Donne et al 2001;Hornbach et al 2003;Reynolds et al 2003;Staron et al 2004]. It was found that the curve of the longitudinal residual stress has a feature of a double peak.…”

Section: Resultsmentioning

confidence: 99%

The simulation of residual stresses in friction stir welds

Zhang

2007

JOMMS

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A numerical model is developed to investigate energy dissipations and residual stress distributions in friction stir welds. Results indicate that the maximum longitudinal residual stress can be increased with the increase of the translational velocity of the pin. But the variation of the angular velocity of the pin does not significantly affect the residual stress distributions. Energy dissipation in friction is increased with the increase of the angular velocity of the pin. However, with the increase of the translational velocity of the pin the plastic dissipation of energy is increased and the frictional dissipation is decreased.

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Residual stress in friction stir-welded Al sheets

Cited by 147 publications

References 7 publications

Contemporary approaches to reducing weld induced residual stress

Contemporary approaches to reducing weld induced residual stress

FE Modelling of Mechanical Tensioning for Controlling Residual Stresses in Friction Stir Welds

The simulation of residual stresses in friction stir welds

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