Thermo-mechanical finite element model of friction stir welding of dissimilar alloys

Al-Badour, Fadi; Merah, Nesar; Shuaib, A. N.; Bazoune, Abdelaziz

doi:10.1007/s00170-014-5680-3

Cited by 120 publications

(32 citation statements)

References 15 publications

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“…where n S is the normal direction of heat dissipation surface, σ b is the Stefan-Boltzmann constant, ε b is the emissivity, T a is the ambient temperature, and h con is the convective heat transfer coefficient. In this study, emissivity of 0.09 was employed for Al6061-T6 [38]. The value of h con was set as 10 W/m 2 • • C with the ambient temperature of 25 • C similar to that of Schmidt H. and Hattel J.…”

Section: Thermal Boundary Conditionsmentioning

confidence: 99%

A Finite Element Model to Simulate Defect Formation during Friction Stir Welding

Zhu

Wang

Zhang

et al. 2017

Metals

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In this study, a 3D coupled thermo-mechanical finite element model is developed to predict and analyze the defect formation during friction stir welding based on coupled Eulerian Lagrangian method. The model is validated by comparing the estimated welding temperature, processed zone shape and void size with those obtained experimentally. The results compared indicate that the simulated temperature and the data measured are in good agreement with each other. In addition, the model can predict the plasticized zone shape and the presence of a void in the weld quite accurately. However, the void size is overestimated. The effects of welding parameters and tool pin profile are also analyzed. The results reveal that welding at low welding speed or high tool rotational speed could produce a smaller void. Moreover, compared to a smooth tool pin, a featured tool pin can enhance plastic flow in the weld and achieve defect-free weldment. The results are helpful for the optimization of the welding process and the design of welding tools.

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Section: Thermal Boundary Conditionsmentioning

confidence: 99%

A Finite Element Model to Simulate Defect Formation during Friction Stir Welding

Zhu

Wang

Zhang

et al. 2017

Metals

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“…It is mostly in plastic state and it is difficult to determine its temperature, due to the large plastic strain values. The FSW process has been considered in [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16], from the point of view of manufacturing, modelling, as well as testing of the specimens cut from the welded joints. Zhang and Zhang [1] carried out semi-coupled thermomechanical finite element (FE) analyses of the FSW process and the associated microstructural changes.…”

Section: Introductionmentioning

confidence: 99%

“…In some references, the main objective was to examine the effect of various FSW process parameters (including tool design) on the heat/mass transport processes, e. g. [1][2][3][4]. Song and Kovačević [5] and Chen and Kovačević [6] presented numerical thermomechanical modeling of FSW for both similar and dissimilar joints; dissimilar joints -------------- were also analysed in [7]. Some simplified analyses are conducted in the literature, such as Dong et al [8], where several models were developed to separately deal with the thermal and mechanical aspects of the FSW.…”

Section: Introductionmentioning

confidence: 99%

Analysis of the tool plunge in friction stir welding - comparison of aluminium alloys 2024 T3 and 2024 T351

et al. 2016

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Temperature, plastic strain and heat generation during the plunge stage of the friction stir welding of high-strength aluminum alloys 2024 T3 and 2024 T351 are considered in this work. The plunging of the tool into the material is done at different rotating speeds. A 3-D finite element model for thermomechanical simulation is developed. It is based on arbitrary Lagrangian-Eulerian formulation, and Johnson-Cook material law is used for modelling of material behaviour. From comparison of the numerical results for alloys 2024 T3 and 2024 T351, it can be seen that the former has more intensive heat generation from the plastic deformation, due to its higher strength. Friction heat generation is only slightly different for the two alloys. Therefore, temperatures in the working plate are higher in the alloy 2024 T3 for the same parameters of the plunge stage. Equivalent plastic strain is higher for 2024 T351 alloy, and the highest values are determined under the tool shoulder and around the tool pin. For the alloy 2024 T3, equivalent plastic strain is the highest in the influence zone of the tool pin.

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“…Since the initial development of such processes and employment for joining metals, a large number of studies have been presented on FSW and FSSW and their modelling [8][9][10][11] other than process parameters. Tool plunge rate during FSSW was investigated in [12].…”

Section: Introductionmentioning

confidence: 99%

Analysis of forces and temperatures in friction spot stir welding of thermoplastic polymers

Paoletti

Lambiase

Ilio

2015

Int J Adv Manuf Technol

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The present investigation analyses the force and torque developing during friction stir spot welding (FSSW) of thermoplastic sheets varying the main process parameters. In addition, measurements of the tool temperature and those of the material close to the welding region were carried out to better understand the variation of the forces during FSSW and quality of the joints. Experimental tests involving an instrumented drilling machine were performed on polycarbonate sheets. The study involved the variation of dwell time, tool plunge rate and rotational speed. Mechanical characterization and dimensional analysis of the joints were performed in order to assess the influence of the process parameters on the joint quality under considered processing conditions. According to the achieved results, using low values of the plunging speed has beneficial effects on both the process (reduction in the force and torque) and the mechanical behaviour of the joints. Increasing the tool rotational speed results in reduced processing forces and higher material mixing and temperature. The dwell time has a negligible effect on developing forces while it highly influences the material temperature, dimension of the welded region and consequently the mechanical behaviour of the joint.

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Thermo-mechanical finite element model of friction stir welding of dissimilar alloys

Cited by 120 publications

References 15 publications

A Finite Element Model to Simulate Defect Formation during Friction Stir Welding

A Finite Element Model to Simulate Defect Formation during Friction Stir Welding

Analysis of the tool plunge in friction stir welding - comparison of aluminium alloys 2024 T3 and 2024 T351

Analysis of forces and temperatures in friction spot stir welding of thermoplastic polymers

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