Steady state thermomechanical modelling of friction stir welding

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

doi:10.1179/174329306x102093

Cited by 97 publications

(73 citation statements)

References 16 publications

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“…As claimed by researchers [98][99][100], the Eulerian formulation was seldom used for thermal analysis of the process, because unlike the Lagrangian method, in the Eulerian formulation the mesh is fixed and the material can move between the boundaries. Therefore, the Eulerian setting was widely used in those processes in which the material travels through the grid such as fluid mechanics problems.…”

Section: Lagrangian Eulerian Methodsmentioning

confidence: 99%

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A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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Friction Stir Welding (FSW) is a novel kind of welding for joining metals that are impossible or difficult to weld by conventional methods. Three-dimensional nature of FSW makes the experimental investigation more complex. Moreover, experimental observations are often costly and time consuming, and usually there is an inaccuracy in measuring the data during experimental tests. Thus, Finite Element Methods (FEMs) has been employed to overcome the complexity, to increase the accuracy and also to reduce costs. It should be noted that, due to the presence of large deformations of the material during FSW, strong distortions of mesh might be happened in the numerical simulation. Therefore, one of the most significant considerations during the process simulation is the selection of the best numerical approach. It must be mentioned that; the numerical approach selection determines the relationship between the finite grid (mesh) and deforming continuum of computing zones. Also, numerical approach determines the ability of the model to overcome large distortions of mesh and provides an accurate resolution of boundaries and interfaces. There are different descriptions for the algorithms of continuum mechanics include Lagrangian and Eulerian. Moreover, by combining the above-mentioned methods, an Arbitrary Lagrangian-Eulerian (ALE) approach is proposed. In this paper, a comparison between different numerical approaches for thermal analysis of FSW at both local and global scales is reviewed and the applications of each method in the FSW process is discussed in detail. Observations showed that, Lagrangian method is usually used for modelling thermal behavior in the whole structure area, while Eulerian approach is seldom employed for modelling of the thermal behavior, and it is usually employed for modelling the material flow. Additionally, for modelling of the heat affected zone, ALE approach is found to be as an appropriate approach. Finally, several significant challenges and subjects remain to be addressed about FSW thermal analysis and opportunities for the future work are proposed.

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Section: Lagrangian Eulerian Methodsmentioning

confidence: 99%

“…A steady state model was investigated by Bastier et al [100]. There were two different stages in the simulation.…”

Section: Lagrangian Eulerian Methodsmentioning

confidence: 99%

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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“…The observed difference has been related to the heat generated, due to a combination of frictional heating and plastic deformation heating, during the FSW process. Using a computational model for FSW of 7075 Al alloy, Bastier et al [25] reported that the overall magnitude of the heat generated due to plastic deformation accounts only for 4.4% of the total heat generation whereas frictional heat generation provides 95.6%. Therefore, the low or high tool rotational speeds influence the frictional conditions and hence the heat distribution in the joint, resulting in different sizes for the SZ and the HAZ.…”

Section: Effect Of Wear On Microstructuresmentioning

confidence: 99%

Tool Wear Characteristics and Effect on Microstructure in Ti-6Al-4V Friction Stir Welded Joints

Fall

Fesharaki

Khodabandeh

et al. 2016

Metals

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Abstract:In the present paper, tool wear and the rate of wear during friction stir welding (FSW) of Ti-6Al-4V alloy are investigated. A conical tungsten carbide tool was used to produce butt-type friction stir welded joints in two-millimeter thick Ti-6Al-4V sheets. An original design of a movable pin allowed for the examination of the tool damage for each process condition. The influence of tool degradation on the quality of the welded joints and the damage brought to the microstructure are examined and discussed. For this purpose, optical and scanning electron microscopies as well as EDX analyses were used to examine the tool wear and the resulting macrostructures and microstructures. The type and nature of the defects are also analyzed as a function of FSW processing parameters. Important geometry and weight variations were observed on the pin and shoulder for all welding conditions, in particular when low tool rotation and travel speeds were used. Experimental results also show that the radial wear of the pin is not uniform, indicating the presence of important frictional temperature gradients through the thickness of the joint. The maximum wear was measured at a location of about one millimeter from the pin root center. Finally, tool rotation was determined as the most significant process parameter influencing both tool wear and microstructure of the joints.

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“…In the literature, one can find both very simple and more sophisticated modellings involving microstructural changes, all of them based on a viscoplastic formalism, whether or not using a plastic threshold. For example, the model of [Myhr and Grong 1991a;1991b] is used in [Bastier et al 2006;Feulvarch et al 2005a;2005b;Feulvarch 2006]; it takes into account the dissolution of precipitates due to the temperature evolution in aluminium alloys.…”

Section: Modelling the Processmentioning

confidence: 99%

A contribution to a critical review of friction stir welding numerical simulation

Lorrain

Serri²,

Favier

et al. 2009

J. Mech. Mater. Struct.

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Various modelling approaches using commercial numerical software have been proposed in the friction stir welding literature. We initiate a comparative analysis of such modellings, involving aspects such as the constitutive laws, the representation of the continuum medium and the contact between medium and tool, and the definition of the heat sources. Numerical problems are also considered: contact definition, mass scaling, and the use of the arbitrary Lagrangian Eulerian in ABAQUS/Explicit. Finally, we propose numerical tests to explore the ability of a Lagrangian code with an ALE option to simulate the process.

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Steady state thermomechanical modelling of friction stir welding

Cited by 97 publications

References 16 publications

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Tool Wear Characteristics and Effect on Microstructure in Ti-6Al-4V Friction Stir Welded Joints

A contribution to a critical review of friction stir welding numerical simulation

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