Numerical Modeling of Multiphysics Field in Conventional and Stationary Shoulder Friction Stir Welding of Al-Cu Alloy

In this study, 2A14-T4 Al-alloy T-joints were prepared via stationary shoulder friction stir welding (SSFSW) technology where the stirring pin’s rotation speed was set as different values. In combination with the numerical simulation results, the macro-forming, microstructure, and mechanical properties of the joints under different welding conditions were analyzed. The results show that the thermal cycle curves in the SSFSW process are featured by a steep climb and slow decreasing variation trends. As the stirring pin’s rotation speed increased, the grooves on the weld surface became more obvious. The base and rib plates exhibit W- or N-shaped hardness distribution patterns. The hardness of the weld nugget zone (WNZ) was high but was lower than that of the base material. The second weld’s annealing effect contributed to the precipitation and coarsening of the precipitated phase in the first weld nugget zone (WNZ1). The hardness of the heat affect zone (HAZ) in the vicinity of the thermo-mechanically affected zone (TMAZ) dropped to the minimum. As the stirring pin's rotation speed increased, the tensile strengths of the base and rib plates first increased and then dropped. The base and rib plates exhibited ductile and brittle/ductile fracture patterns, respectively.

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Investigation on friction stir welding of hybrid composites fabricated on Al–Zn–Mg–Cu alloy through friction stir processing

Journal of Materials Research and Technology ◽

10.1016/j.jmrt.2019.06.033 ◽

2019 ◽

Vol 8 (5) ◽

pp. 3733-3740 ◽

Cited By ~ 6

Author(s):

Namrata Gangil ◽

Sachin Maheshwari ◽

Arshad Noor Siddiquee ◽

Mustufa Haider Abidi ◽

Mohammed A. El-Meligy ◽

...

Keyword(s):

Friction Stir Welding ◽

Friction Stir Processing ◽

Hybrid Composites ◽

Friction Stir ◽

Cu Alloy

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A Comparative Investigation on Conventional and Stationary Shoulder Friction Stir Welding of Al-7075 Butt-Lap Structure

Metals ◽

10.3390/met9121264 ◽

2019 ◽

Vol 9 (12) ◽

pp. 1264 ◽

Cited By ~ 1

Author(s):

Yu Chen ◽

Huaying Li ◽

Xiaoyu Wang ◽

Hua Ding ◽

Fenghe Zhang

Keyword(s):

Friction Stir Welding ◽

Material Flow ◽

Comparative Investigation ◽

Flow Mode ◽

Nugget Zone ◽

Friction Stir ◽

Stationary Shoulder ◽

Average Grain Size ◽

Al 7075

Both conventional friction stir welding (C-FSW) and stationary shoulder friction stir welding (S-FSW) were employed to join the Al-7075 butt-lap structure, then the microstructural evolution and mechanical characterization of all FSW joints were systematically studied. The C-FSW joint exhibited a rough surface with flashes and arc corrugations, while the surface of the S-FSW joint became smooth. Moreover, for the S-FSW joint, the shoulder-affected zone got eliminated and the material flow mode during FSW was changed owning to the application of stationary shoulder. Furthermore, in comparison to C-FSW, the lower welding heat input of S-FSW decreased the average grain size in the nugget zone and inhibited the coarsening of strengthening precipitates in the heat-affected zone, elevating the overall hardness for the S-FSW joint. In addition, the tensile strength of the S-FSW joint became higher compared to the C-FSW joint, and all the FSW joints failed inside the nugget zone attributing to the existence of hook defect. The sharp-angled hook defect deteriorated the plasticity of the C-FSW joint further, which was only 70% that of the S-FSW joint.

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Probing residual stresses in stationary shoulder friction stir welding process

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-019-04570-9 ◽

2019 ◽

Vol 106 (5-6) ◽

pp. 1573-1586 ◽

Cited By ~ 5

Author(s):

B. Vicharapu ◽

H. Liu ◽

H. Fujii ◽

K. Narasaki ◽

N. Ma ◽

...

Keyword(s):

Friction Stir Welding ◽

Residual Stresses ◽

Welding Process ◽

Friction Stir ◽

Friction Stir Welding Process ◽

Stationary Shoulder

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Stationary shoulder supporting and tilting pin penetrating friction stir welding

Journal of Materials Processing Technology ◽

10.1016/j.jmatprotec.2018.01.010 ◽

2018 ◽

Vol 255 ◽

pp. 596-604 ◽

Cited By ~ 8

Author(s):

Huijie Liu ◽

Yanying Hu ◽

Huan Wang ◽

Shuaishuai Du ◽

Dusan P. Sekulic

Keyword(s):

Friction Stir Welding ◽

Friction Stir ◽

Stationary Shoulder

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Vacancy-induced θ′ precipitation during ultrasonic-affected friction stir welding of Al–Cu alloy

Journal of Materials Science ◽

10.1007/s10853-020-05061-z ◽

2020 ◽

Vol 55 (29) ◽

pp. 14626-14641

Author(s):

Yanying Hu ◽

Huijie Liu ◽

Hidetoshi Fujii ◽

Kohsaku Ushioda ◽

Hideki Araki ◽

...

Keyword(s):

Friction Stir Welding ◽

Friction Stir ◽

Cu Alloy

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The strengthening mechanism of spray forming Al-Zn-Mg-Cu alloy by underwater friction stir welding

Materials & Design ◽

10.1016/j.matdes.2016.04.036 ◽

2016 ◽

Vol 102 ◽

pp. 91-99 ◽

Cited By ~ 44

Author(s):

Qingzhao Wang ◽

Zhixia Zhao ◽

Yong Zhao ◽

Keng Yan ◽

Chuan Liu ◽

...

Keyword(s):

Friction Stir Welding ◽

Strengthening Mechanism ◽

Spray Forming ◽

Friction Stir ◽

Cu Alloy ◽

Underwater Friction Stir Welding

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Numerical Modeling of Thermal Field Distribution during Friction Stir Welding (FSW) of Dissimilar Materials

Solid State Phenomena ◽

10.4028/www.scientific.net/ssp.254.261 ◽

2016 ◽

Vol 254 ◽

pp. 261-266

Author(s):

Bogdan Radu ◽

Cosmin Codrean ◽

Radu Cojocaru ◽

Cristian Ciucă

Keyword(s):

Numerical Modeling ◽

Friction Stir Welding ◽

Solid State ◽

Thermal Field ◽

Welding Process ◽

Dissimilar Materials ◽

Dissimilar Joints ◽

Element Analysis ◽

Friction Stir ◽

The Cost

Friction Stir Welding (FSW) is an innovative solid state welding process, relatively new in industry, which allow welding of two or more materials which have very different properties, particularly thermal properties as fusion temperature, thermal expansion coefficient, specific heat and thermal conduction and have a predisposition to form intermetallic brittle phases, neither one of the components to be weld reach to the melting point. Being a solid state welding process temperature field is very important for the quality of the welded joint, and a lot of researches focused on this topic. This paper presents some results in modeling and estimation of thermal field developed during FSW of dissimilar joints, using Finite Element Analysis. Numerical modeling of thermal field allows engineers to predict, in advance, the evolution of temperature and to estimate the behavior of the welded materials during the welding process. This will reduce significantly the time and number of experiments that have to be carried out, in the process of establishing a good FSW technology, as well as reducing significantly the cost of the tests.

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