A study on the variation of forces and temperature in a friction stir welding process: A finite element approach

AbstractIn an effort to enhance safety for long time disposal of waste nuclear fuel, friction stir welding has been developed as one alternative to seal copper canisters. To avoid the formation of voids and cracks during the welding process, an understanding of the heat and material flow andthereby the evolution of the microstructure, is of great importance. Finite element modelling has been used to simulate the heat and material flow as well as thermal expansion during the friction stir welding process. A model involving heat transfer, material flow, and continuum mechanics has been developed. The steady state solutions have been compared with experimental temperature observations as well as analytical solutions, showing good agreement. Temperature distribution is affected by the welding speed. For a given reference pointperpendicular to the welding direction, a lower welding speed corresponds to a higher peak temperature. The plunging position of welding tool influences the temperature distribution and therefore the displacement distribution of the weldment.

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Modelling of entire friction stir welding process by explicit finite element method

Materials Science and Technology ◽

10.1179/1743284711y.0000000087 ◽

2012 ◽

Vol 28 (7) ◽

pp. 812-817 ◽

Cited By ~ 19

Author(s):

M Yu ◽

W Y Li ◽

J L Li ◽

Y J Chao

Keyword(s):

Finite Element Method ◽

Finite Element ◽

Friction Stir Welding ◽

Welding Process ◽

Explicit Finite Element Method ◽

Explicit Finite Element ◽

Friction Stir ◽

Friction Stir Welding Process ◽

Element Method

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Experimental studies on friction stir welding of aluminium alloy 5083 and prediction of temperature distribution using arbitrary Lagrangian–Eulerian-based finite element method

Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications ◽

10.1177/14644207211068118 ◽

2021 ◽

pp. 146442072110681

Author(s):

R Pramod ◽

Vikram Kumar S Jain ◽

S Mohan Kumar ◽

B Girinath ◽

A Rajesh Kannan ◽

...

Keyword(s):

Finite Element ◽

Friction Stir Welding ◽

Aluminium Alloy ◽

Process Parameters ◽

Experimental Studies ◽

Welding Process ◽

Element Model ◽

Arbitrary Lagrangian Eulerian ◽

Friction Stir ◽

Friction Stir Welding Process

The present work focused on welding aluminium alloy 5083 using the friction stir welding process. Suitable welding process parameters were identified to fabricate a defect-free butt joint with a tool rotational speed of 1600 rpm, traverse speed of 20 mm/min and tilt angle of 3°. The microstructure at the nugget zone, thermo mechanically affected zone, heat-affected zone and base metal zone are examined. Mechanical properties of the weldment exhibited promising results with an average joint efficiency and hardness of 75.70% and 94.0 ± 5.0 vickers hardness, respectively. Fractography revealed ductile mode of failure in base and weld metal tensile samples. Furthermore, a 3D thermomechanical finite element model was utilized to simulate the friction stir welding process using the selected process parameters. Arbitrary Lagrangian–Eulerian-based model aided in predicting residual stress distributions and thermal history during the friction stir welding process.

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