Thermo-Mechanical Investigations during Friction Stir Spot Welding (FSSW) of AA6082-T6

This study presents an investigation of the plunge stage in joining AZ31B magnesium alloy with friction stir welding using two different 3D finite element models based on Arbitrary Lagrangian–Eulerian formulation and Coupled Eulerian–Lagrangian formulation. The investigations are made with the ABAQUS program. Johnson–Cook plastic material law and Coulomb friction law are used in both models. Models are compared in terms of temperature, strain distribution, and processing time. In both models, very similar temperature and strain distributions are obtained in the weld zone and the models are validated by experimental results. In addition, with the increase in the rotational speed of the tool, temperature and strain in the welding zone increase similarly in both models. In the model using the Arbitrary Lagrangian–Eulerian formulation, mesh distortions occur when high mesh density is not created in the plunge zone. No problems related to mesh distortion are encountered in the model using Coupled Eulerian–Lagrangian formulation. Moreover, it is found that the model using the Coupled Eulerian–Lagrangian formulation has a lower processing time and this processing time is not affected by the rotational speed of the tool.

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“…Mass scaling method can be utilized to minimize simulation time [28]. In this study, mass scaling method was used.…”

Section: Verifying Mass Scalingmentioning

confidence: 99%

Two different finite element models investigation of the plunge stage in joining AZ31B magnesium alloy with friction stir welding

Türkan

Karakaş

2021

SN Appl. Sci.

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“…Scarce studies have used temperature-dependent COF for modelling the contact during welding. Khosa et al 21 employed a temperature-dependent friction coefficient determined using an inverse approach. They developed a 2D numerical model to simulate the FSSW of AA6082-T6 aluminium alloy and a comparison with experimental results was performed.…”

Section: Introductionmentioning

confidence: 99%

Thermo-mechanical modelling of the Friction Stir Spot Welding process: Effect of the friction models on the heat generation mechanisms

Hannachi

Khalfallah

Leitão

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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Friction Stir Spot Welding involves complex physical phenomena, which are very difficult to probe experimentally. In this regard, the numerical simulation may play a key role to gain insight into this complex thermo-mechanical process. It is often used to mimic specific experimental conditions to forecast outputs that may be substantial to analyse and elucidate the mechanisms behind the Friction Stir Spot Welding process. This welding technique uses frictional heat generated by a rotating tool to join materials. The heat generation mechanisms are governed by a combination of sliding and sticking contact conditions. In the numerical simulation, these contact conditions are thoroughly dependent on the used friction model. Hence, a successful prediction of the process relies on the appropriate selection of the contact model and parameters. This work aims to identify the pros and cons of different friction models in modelling combined sliding-sticking conditions. A three-dimensional coupled thermo-mechanical FE model, based on a Coupled Eulerian-Lagrangian formulation, was developed. Different friction models are adopted to simulate the Friction Stir Spot Welding of the AA6082-T6 aluminium alloy. For these friction models, the temperature evolution, the heat generation, and the plastic deformation were analysed and compared with experimental results. It was realized that numerical analysis of Friction Stir Spot Welding can be effective and reliable as long as the interfacial friction characteristics are properly modelled. This approach may be used to guide the contact modelling strategy for the simulation of the Friction Stir Spot Welding process and its derivatives.

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“…These factors can be divided into two major categories of welding parameters, such as tool rotational speed, dwell time, delay time, plunge depth, and plunge rate as well as tool geometrical factors, such as pin diameter, pin length, pin angle, pin profile, shoulder diameter, and the shoulder concavity angle. The research presented by Mishra (Mishra and Ma 2005) and Khosa (Khosa et al 2010) showed that in a fixed welding process parameter, the heat generation and plastic flow of the material are only affected by tool geometrical factors. The previous studies were mainly focused on obtaining optimum FSSW joints by changing the various affecting parameters.…”

Section: Introductionmentioning

confidence: 99%

“…The research presented by Mishra and Ma 13 and Khosa et al. 14 showed that in a fixed welding process parameter, the heat generation and plastic flow of the material are only affected by tool geometrical factors. The previous studies were mainly focused on obtaining optimum FSSW joints by changing the various affecting parameters.…”

Section: Introductionmentioning

confidence: 99%

Analysis of tensile-shear strength of single and multi-friction stir spot welding joints under fixed welding process conditions

Asadollahi

Jabbari

Nakhodchi

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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The tensile-shear strength of AA 5052 single and multi-friction stir spot welding joints were analyzed using experimental, numerical, and analytical approaches. Benchmark specimens were designed and manufactured in a similar manner with respect to industrial practice. Under the fixed welding process condition, the failure mechanism of friction stir spot welded specimens under tensile-shear loading was first determined by using macro- and micro-structural analysis. It is shown that increasing the tool shoulder diameter and the number of friction stir spot weldings may nonproportionally increase the strength of the joints. In the linearly arranged multi-friction stir spot welding joints, the strength of these joints was discussed using analytical approach. It is demonstrated that in certain cases, increasing the nugget diameter is preferred than increasing the number of nuggets. This is only applicable to a certain friction stir spot welding failure mechanism. A finite element model prediction tool was developed to predict the tensile-shear strength of friction stir spot welded joints using the material properties obtained from the measurement of experimental hardness.

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Thermo-Mechanical Investigations during Friction Stir Spot Welding (FSSW) of AA6082-T6

Cited by 28 publications

References 21 publications

Two different finite element models investigation of the plunge stage in joining AZ31B magnesium alloy with friction stir welding

Two different finite element models investigation of the plunge stage in joining AZ31B magnesium alloy with friction stir welding

Thermo-mechanical modelling of the Friction Stir Spot Welding process: Effect of the friction models on the heat generation mechanisms

Analysis of tensile-shear strength of single and multi-friction stir spot welding joints under fixed welding process conditions

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