Numerical determination of residual stress in friction stir weld using 3D-analytical model of stir zone

The demand for lighter materials with suitable mechanical properties and a high resistance to corrosion has been increasing in the industries. Therefore, aluminum appears as an alternative due to its set of properties. The aim of this work was to evaluate residual stress levels and mechanical properties of welded joints of Aluminum-Magnesium alloy AA 5083-O using the Friction Stir Welding process. For mechanical characterization were performed a uniaxial tensile test, Vickers hardness, bending test and, finally, the determination of residual stresses. It was concluded that welding by FSW process with an angle of inclination of the tool at 3o, established better results due to better mixing of materials. The best results of tensile strength and a lower level of residual stresses were obtained using a tool rotation speed of 340 RPM with welding advance speed of 180 mm/min and 70 mm/min.

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WITHDRAWN: Analysis of the unstressed lattice spacing, d0, for the determination of the residual stress in a friction stir welded plate of AA7075 alloy – Use of equilibrium conditions and a genetic algorithm

Acta Materialia ◽

10.1016/j.actamat.2013.12.026 ◽

2014 ◽

Author(s):

F. Cioffi ◽

J.I. Hidalgo ◽

R. Fernández ◽

T. Pirling ◽

B. Fernández ◽

...

Keyword(s):

Genetic Algorithm ◽

Residual Stress ◽

Lattice Spacing ◽

Equilibrium Conditions ◽

Friction Stir

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Residual stress distribution and microstructure in the friction stir weld of 7075 aluminum alloy

Journal of Materials Science ◽

10.1007/s10853-015-9280-x ◽

2015 ◽

Vol 50 (22) ◽

pp. 7262-7270 ◽

Cited By ~ 7

Author(s):

Pengfei Ji ◽

Zhongyu Yang ◽

Jin Zhang ◽

Lin Zheng ◽

Vincent Ji ◽

...

Keyword(s):

Residual Stress ◽

Aluminum Alloy ◽

Stress Distribution ◽

Residual Stress Distribution ◽

Friction Stir Weld ◽

7075 Aluminum Alloy ◽

Friction Stir

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Effect of Residual Stress on the Mechanical Properties of FSW Joints with SUS409L

Advances in Materials Science and Engineering ◽

10.1155/2018/9890234 ◽

2018 ◽

Vol 2018 ◽

pp. 1-8 ◽

Cited By ~ 3

Author(s):

Yeong-Seok Lim ◽

Sang-Hyuk Kim ◽

Kwang-Jin Lee

Keyword(s):

Mechanical Properties ◽

Residual Stress ◽

Residual Stresses ◽

Welded Joints ◽

Stress Measurement ◽

Charpy Impact ◽

Stir Zone ◽

Hole Drilling ◽

Friction Stir ◽

Compressive Residual Stresses

This study was performed to investigate both the residual stress distribution and the effect of the residual stress formed at the welding region on the mechanical properties of the friction stir welded joints with 409L stainless steel sheets. Residual stress measurement with hole-drilling method; mechanical property evaluation including tensile test, Charpy impact test, and fatigue test; and microstructure observation were conducted. It has got no residual stresses to speak of at the center region of the stir zone because the stored stresses are released in the process of the dynamic recrystallization, while a small quantity of compressive residual stresses is formed at the surface region of the stir zone because of strong compression reaction by the tool shoulder. A considerable amount of compressive residual stresses is formed at the thermomechanical affected zone because of the synergy between the thermal expansion due to the heat conduction from the stir zone and mechanical compression by the tool. The formation of residual stresses shows a similar tendency between the advancing side and the retreating side. Both the mitigation of residual stress in the stir zone and the formation of compressive residual stress in the thermomechanical affected zone contribute to the improvement of the mechanical properties of the friction stir welded joints.

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Residual stress measurements in a thick, dissimilar aluminum alloy friction stir weld

Acta Materialia ◽

10.1016/j.actamat.2006.04.034 ◽

2006 ◽

Vol 54 (15) ◽

pp. 4013-4021 ◽

Cited By ~ 188

Author(s):

M PRIME ◽

T GNAUPELHEROLD ◽

J BAUMANN ◽

R LEDERICH ◽

D BOWDEN ◽

...

Keyword(s):

Residual Stress ◽

Aluminum Alloy ◽

Friction Stir Weld ◽

Friction Stir ◽

Stress Measurements

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A new distributed cooling method for mitigating residual stress in friction stir welding

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405415573849 ◽

2016 ◽

Vol 230 (12) ◽

pp. 2204-2213 ◽

Cited By ~ 3

Author(s):

Xingguo Zhou ◽

Donald Mackenzie ◽

Wenke Pan

Keyword(s):

Residual Stress ◽

Finite Element ◽

Cryogenic Cooling ◽

Friction Stir Weld ◽

Finite Element Models ◽

Welding Temperature ◽

Friction Stir ◽

Longitudinal Residual Stress ◽

Cooling Methods ◽

Cooling Model

An analytical and finite element investigation of the effect of different cryogenic cooling nozzle configurations on temperature and residual stress in a model friction stir weld is presented. A new configuration adopting a distributed cooling approach is proposed based on an analytical cooling model. Finite element models are implemented to verify the effect of distributed cooling on welding temperature and longitudinal residual stress. The results presented indicate that new active cooling methods can improve mitigation of welding-induced residual stress.

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The investigation into vibration effect on microstructure and mechanical characteristics of friction stir spot vibration welded aluminum: Simulation and experiment

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/0954406219900194 ◽

2020 ◽

Vol 234 (9) ◽

pp. 1809-1822 ◽

Cited By ~ 6

Author(s):

Behrouz Bagheri ◽

Mahmoud Abbasi ◽

Reza Hamzeloo

Keyword(s):

Residual Stress ◽

Finite Element ◽

Shear Strength ◽

Finite Element Simulation ◽

Stir Zone ◽

Tensile Shear Strength ◽

Tensile Shear ◽

Friction Stir ◽

Element Simulation ◽

Workpiece Vibration

In this study, an innovative technique is employed to modify the microstructure and increase the mechanical characteristics of the Al5083 joint made by friction stir spot welding (FSSW). In this technique entitled FSSVW (friction stir spot vibration welding), the workpiece is vibrated during FSSW. Noted processes were modeled and finite element simulation results were also analyzed. The results showed that workpiece vibration during FSSW led to grain refinement, larger weld region, and improvement of the mechanical properties, namely tensile shear strength and hardness, of the joint. Stir zone grain size decreased by about 25% and tensile shear strength value increased by about 20% by applying workpiece vibration during FSSW. The results also indicated that the tensile shear strength and hardness enhanced, as vibration frequency increased. It was concluded that the presence of vibration increased the material deformation in the stir zone and led to enhanced deformation of the material. This intensified the dynamic recrystallization and resulted in grain refinement. It was also found that tensile residual stresses developed in the stir zone of FSS and FSSV welded specimens and tensile residual stress values for FSSV welded specimens were higher than those for FSS welded specimens for about 10%. It was concluded that the effect of grain size on hardness is higher than the effect of residual stress. Higher ductility is predicted for FSSV welded specimen with higher vibration frequency and also for specimen welded with less dwell time; finite element simulation was also applied to analyze the effects of workpiece vibration during FSSW on strain distribution as well as hardness and residual stress distribution within the joint during FSSW and FSSVW processes. Finite element simulation results had good compatibility with experimental results. It was concluded that the strain values and flow velocity relating to the FSSVW process are higher than those relating to the FSSW process.

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