Three-Dimensional Numerical Model Considering Phase Transformation in Friction Stir Welding of Steel

Cho, Hoon-Hwe; Kim, Dong-Wan; Hong, Sung-Tae; Jeong, Yong-Ha; Lee, Keunho; Cho, Yigil; Kang, Suk Hoon; Han, Heung Nam

doi:10.1007/s11661-015-3177-9

Cited by 11 publications

(5 citation statements)

References 37 publications

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“…Heat equation Here, the Eulerian algorithm is used in which the FSW tool is represented as solid whereas the workpiece material is represented as liquid and flows through the mesh usually in steady-state solution [2,19] :…”

Section: The Governing Equationsmentioning

confidence: 99%

Modelling of friction stir welding of DH36 steel

Al-moussawi

Smith

Young

et al. 2017

Int J Adv Manuf Technol

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A 3-D computational fluid dynamics (CFD) model was developed to simulate the friction stir welding of 6-mm plates of DH36 steel in an Eulerian steady-state framework. The viscosity of steel plate was represented as a nonNewtonian fluid using a flow stress function. The PCBN-WRe hybrid tool was modelled in a fully sticking condition with the cooling system effectively represented as a negative heat flux. The model predicted the temperature distribution in the stirred zone (SZ) for six welding speeds including low, intermediate and high welding speeds. The results showed higher asymmetry in temperature for high welding speeds. Thermocouple data for the high welding speed sample showed good agreement with the CFD model result. The CFD model results were also validated and compared against previous work carried out on the same steel grade. The CFD model also predicted defects such as wormholes and voids which occurred mainly on the advancing side and are originated due to the local pressure distribution between the advancing and retreating sides. These defects were found to be mainly coming from the lack in material flow which resulted from a stagnant zone formation especially at high traverse speeds. Shear stress on the tool surface was found to increase with increasing tool traverse speed. To produce a "sound" weld, the model showed that the welding speed should remain between 100 and 350 mm/min. Moreover, to prevent local melting, the maximum tool's rotational speed should not exceed 550 RPM.

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Section: The Governing Equationsmentioning

confidence: 99%

Modelling of friction stir welding of DH36 steel

Al-moussawi

Smith

Young

et al. 2017

Int J Adv Manuf Technol

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“…This is a very important stage because during this time, the temperature significantly increases, which allows material to flow around the probe. These two phenomena are complex and coupled and affect the material microstructure which, as a consequence, affects the material behaviour under external loads [8,[15][16][17]22]. The ensuing plastic deformation and its directions are related to the tool geometry and the motion of this tool; therefore, the asymmetry in stirred zone is an important subject of observation (Fig.…”

Section: Modelmentioning

confidence: 99%

“…During the FSP process, the tool affects the workpiece and the parameters (rotation speed and feed rate) determine the amount of generated heat energy and the manner of material flow [14]. The material behaviour of individual zones in FSP composites is closely related to the microstructures of the zones which are determined by influence of the tool [15][16][17]. Friction stir processing is a variation of a friction stir welding technology which was developed at the end of the twentieth century by Wayne Thomas in the Welding Institute (UK) [18].…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation of temperature distribution during the first stage of the friction stir alloying process

2018

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This work demonstrates the numerical modelling of thermal dispersion accompanying the first stage of the friction stir alloying process. It is very important to recognise the temperature field in the modified workpiece in order to identify the zones where the physical material properties are changing. The temperature gradient leads to a drop of yield strength of the material and, as a consequence, the occurrence of the possibility of plastic flow around the tool. an attempt has been made to analyse the axisymmetric thermal problem described by a fourier equation with an internal heat source in which the heat is derived only from work of frictional forces occurring between the workpiece and the tool material. The example under consideration focuses on the production of an al-TiC composite using fsa technology. macrostructure images of the composite and the simulation results confirm the correctness of the applied mathematical model, where the obtained temperature field corresponds with specific fsa zones.

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“…The process involves a rotating and traversing tool with a pin that inserts into the material to plasticize it and a shoulder that creates frictional heat. [8,9] Due to its usefulness, there have been numerous studies on the application of this joining procedure on the combination of various materials to achieve sound joints for a variety of applications. It is well documented that FSW often leads to a typical joint consisting of three regions: stir zone (SZ), thermomechanically affected zone, and heat-affected zone, with each region having distinct microstructural and corresponding mechanical and electrochemical properties.…”

Section: Introductionmentioning

confidence: 99%

Numerical Investigation of the Galvanic Corrosion Behavior of a Joint between Steel and Aluminum Alloys Produced by Friction Stir Joining

Anaman

Kim

Lee

et al. 2022

steel research int.

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This study establishes a numerical model to study the galvanic corrosion behaviors of four galvanic couples located along the front and the back surfaces of a friction stir welded joint of dual-phase steel and aluminum alloys joined at an offset of 0.5 mm and exposed to a neutral environment. The results are initially validated with the experimental methods and are found to be in good agreement. The galvanic corrosion behaviors of the couples are further explored by subjecting the model to some electrochemical scenarios, such as the effects of electrolyte depth and cathode-to-anode surface area ratios. Furthermore, the model is capable of tracking the moving boundaries of the corroding surfaces of the galvanic couples. This overall approach presented herein provides a suitable framework for understanding the galvanic corrosion behavior that exists along a heterogeneous joint involving multiple galvanic couples.

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Three-Dimensional Numerical Model Considering Phase Transformation in Friction Stir Welding of Steel

Cited by 11 publications

References 37 publications

Modelling of friction stir welding of DH36 steel

Modelling of friction stir welding of DH36 steel

Numerical simulation of temperature distribution during the first stage of the friction stir alloying process

Numerical Investigation of the Galvanic Corrosion Behavior of a Joint between Steel and Aluminum Alloys Produced by Friction Stir Joining

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