Ultimate tensile strength optimization of different FSW aluminium alloy joints

Silva, A.; Braga, Daniel F.O.; Figueiredo, Miguel; Moreira, P.M.G.P.

doi:10.1007/s00170-015-6871-2

Cited by 41 publications

(28 citation statements)

References 22 publications

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“…Although FSW is often employed as a technique for welding aluminum alloys [13,14], but it has also been used for welding of many other metals such as magnesium alloys [15,16], titanium alloys [17,18] and metal-matrix composites [19,20]. Moreover, similar or dissimilar materials in different thickness can be welded by this method.…”

Section: Introductionmentioning

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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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: Introductionmentioning

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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“…Moreover, clamping and fixturing can easily use existing vises and clamps of the CNC machining center since the required holding force is lower [5,6]. Until now, FSW has primarily been employed to produce butt joints [7,8] and sometimes for a lap joint. By developing FSW techniques for lap joints, the number of applications of this technique would expand, drastically.…”

Section: Introductionmentioning

confidence: 99%

Effect of Tool Design and Process Parameters on Lap Joints Made by Right Angle Friction Stir Welding (RAFSW)

Momeni

Guillot

2019

JMMP

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In recent decades, friction stir welding (FSW) has attracted extensive attention of academic and industrial sectors as the most considerable development in metal joining processes. FSW lap joint is an interesting alternative for rivets, fusion welds and bonding particularly in the transportation industry. In this paper, the effect of tool design and process parameters on the generated downward axial force and strength of AA6061-T6 lap joints is studied. The welds are made by a low-cost friction stir welding technique at right angle (RAFSW). The studied tool design parameters are shoulder diameter, shoulder groove depth, pin length, pin angle, pin base diameter and pin lead. Moreover, the effect of tool rotational speed, traverse speed, plunge depth and lap joint configuration is evaluated. The Taguchi method is used to design the experiments and artificial neural network (ANN) modeling is applied to predict the plunging force and the strength of the joints. The results indicate that a quality weld can be obtained at low downward axial forces during welding by proper selection of tool design and process parameters. It is identified that one can achieve a quality lap joint at traverse speeds as high as 1400 mm/min and downward axial forces as low as 3.2 kN by a low-cost RAFSW technique.

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“…The rotation speed of the welding tool is an important control variable of heat generation during FSW [2]. Traditionally, the rotation speeds less than 3000 rpm were applied to welding tool during FSW [3].…”

Section: Introductionmentioning

confidence: 99%

Effect of rotation speed on nugget structure and property of high rotation speed friction stir welded Al-Mn aluminum alloy

Zhang

Wang

et al. 2017

Int J Adv Manuf Technol

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High rotation speed friction stir welding is a promising low-force welding technique that enables the application of friction stir welding on in situ fabrication and repair. High rotation speed friction stir welding experiments (above 3000 rpm) were conducted on an Al-Mn aluminum alloy. The effect of rotation speed on nugget structure and property was investigated in order to illuminate the process features. The results indicate that a notable increase of nugget size occurs at high rotation speeds of 5000-8000 rpm. With increasing rotation speed, the thermal effect is firstly strengthened and then achieves a steady state. The microstructure evolution is more sensitive to welding temperature as rotation speed varies, and thus, the evolution trends of nugget structure morphology (grain size and substructure distribution density) with rotation speed resemble that of welding temperature. Increasing rotation speed above 4000 rpm effectively improves the nugget hardness due to the enhancement of strain hardening.

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Ultimate tensile strength optimization of different FSW aluminium alloy joints

Cited by 41 publications

References 22 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)

Effect of Tool Design and Process Parameters on Lap Joints Made by Right Angle Friction Stir Welding (RAFSW)

Effect of rotation speed on nugget structure and property of high rotation speed friction stir welded Al-Mn aluminum alloy

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