Visualisation and numerical simulation of material flow behaviour during high-speed FSW process of 2024 aluminium alloy thin plate

Qin, Dingqiang; Fu, Li; Shen, Zhikang

doi:10.1007/s00170-018-03241-5

Cited by 24 publications

(5 citation statements)

References 37 publications

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“…The study examined the material flow during ultra-thin 2024 aluminum alloy plate friction stir welding [179]. The copper powder was utilized as a marker material to track the material flow.…”

Section: Materials Flow During the Fsw Processmentioning

confidence: 99%

A Review on Friction Stir Welding/Processing: Numerical Modeling

Akbari,

Asadi,

Sadowski

2023

Materials

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Friction stir welding (FSW) is a manufacturing process that many industries have adopted to join metals in a solid state, resulting in unique properties. However, studying aspects like temperature distribution, stress distribution, and material flow experimentally is challenging due to severe plastic deformation in the weld zone. Therefore, numerical methods are utilized to investigate these parameters and gain a better understanding of the FSW process. Numerical models are employed to simulate material flow, temperature distribution, and stress state during welding. This allows for the identification of potential defect-prone zones. This paper presents a comprehensive review of research activities and advancements in numerical analysis techniques specifically designed for friction stir welding, with a focus on their applicability to component manufacturing. The paper begins by examining various types of numerical methods and modeling techniques used in FSW analysis, including finite element analysis, computational fluid dynamics, and other simulation approaches. The advantages and limitations of each method are discussed, providing insights into their suitability for FSW simulations. Furthermore, the paper delves into the crucial variables that play a significant role in the numerical modeling of the FSW process.

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Section: Materials Flow During the Fsw Processmentioning

confidence: 99%

A Review on Friction Stir Welding/Processing: Numerical Modeling

Akbari,

Asadi,

Sadowski

2023

Materials

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“…The general proven principle of recrystallization as mentioned by Wang et al [45]states that the reduced deformation degree during the employment of FSW for joining will result in a raise in the size of the recrystallized grains. This escalation in the size of the grains will be usually associated with various weld deformities including surface galling, tunneling flaws, porosities, etc [46,47]. Table 2 reveals us the same fact, as it can be seen in this table that, the joints fabricated at higher speeds of traverse of tool were found to possess above mentioned defects and at the same time, the joints fabricated at a lower speed of traverse of the tool (i.e., 20 mm/min) were completely free from defects.…”

Section: Characterization Of Macrostructuresmentioning

confidence: 99%

Impact of speed of traverse during joining of CDA101 plates by FSW process

Kumar¹,

Sevvel²

2022

Scientia Iranica

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An experimental investigation was carried out to comprehend the impact of speed of traverse of tool on tensile strength and micro-structural peculiarities of attained joints during friction stir welding of Cu alloy namely CDA 101 flat plates, with other parameters namely spinning speed of tool (1100 rpm) and downward force (6kN) being constant. A tool with cylindrical tapered pin geometry was made to traverse at distinctive speeds from 20 mm/min to 45 mm/min. It was observed that, the CDA 101 joints fabricated at 20 mm/min was found to be entirely free flaws, with joints fabricated at other speeds of tool traverse possessing several weld flaws. Grains in the center of the zone of stir of the joints obtained at 20 mm/min was uniformly distributed and homogeneous, due to the experience of the exemplary volume of frictional heat and sufficient amount of stirring force. Highest tensile strength of 200.65 MPa (nearly 85.38% of base metal)was exhibited by joint attained at 20 mm/min.

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“…In the FSW, the relation between mechanical properties and the process' input parameters should be established by a model. The dependence of mechanical properties on parameters of the FSW has been meaningfully approved through various studies [9]. Parameters of the process are entirely based on experiences or extracted from the database [10].…”

Section: Introductionmentioning

confidence: 99%

Prediction of mechanical properties and hardness of friction stir welding of Al 5083/pure Cu using ANN, ICA and PSO model

et al. 2022

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The effect of parameters involved in prediction of mechanical properties of Friction Stir Welding have been investigated in this study through modeling. For this purpose, the friction stir welding on both sheets of 5083 Aluminum (Al5083) and pure Copper (Cu) was experimentally conducted at first level. Three factors of Rotation Speed (RPM), Traverse Speed (mm/min) and the Tool’s pin angle was examined. During the tentative test, many experiments were not satisfactorily performed. Thanks to a more rigorous study hypothesis, proper samples were obtained by changing the geometry of different tools. In order to overcome the softness of aluminum sheets and the rise of shoulder diameter, and also to avoid the vertical instability of the sheet, shortening the pin’s length was suggested. In this paper, the Full Factorial method has been employed to evaluate the result of Artificial Neural Networks (ANN), Imperialist Competitive Algorithm, Particle Swarm Optimization, and also the effects of input parameters of the process on output parameters. Moreover, Al5083 and Cu joining sheets were analyzed. Micro-hardness and tensile tests have been based on the process’ input parameters to obtain mechanical properties. The function of ANN model demonstrates that it can estimate the number of mechanical properties with an adequate precision. Using the evaluation factors of mechanical properties and micro-hardness and also a R2 ~ 0.943 analysis, the optimum parameters of Al5083 and Cu joining sheets can be anticipated. The rotation speed of 1150 rpm, traverse speed of 40 mm/min, and pin angle of 2° are the optimum conditions based on the average review of analyses. These optimum conditions led to improve the maximum tensile force up to 15 ~ 21%.

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Visualisation and numerical simulation of material flow behaviour during high-speed FSW process of 2024 aluminium alloy thin plate

Cited by 24 publications

References 37 publications

A Review on Friction Stir Welding/Processing: Numerical Modeling

A Review on Friction Stir Welding/Processing: Numerical Modeling

Impact of speed of traverse during joining of CDA101 plates by FSW process

Prediction of mechanical properties and hardness of friction stir welding of Al 5083/pure Cu using ANN, ICA and PSO model

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