Review on Thermo-Mechanical and Material Flow Analysis of Dissimilar Friction Stir Welding

2021 ◽  
Author(s):  
Rituraj Bhattacharjee ◽  
Pankaj Biswas
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
Friction Stir ◽  
Dissimilar Friction Stir Welding

Control of Material Flow During Friction Stir Welding Between Aluminum and Steel by Welding Tool Shape

2020 ◽  
Author(s):  
Toshiaki Yasui ◽  
Yuki Ogura ◽  
Xu Huilin ◽  
F. Farrah Najwa ◽  
Daichi Sugimoto ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Simulation Experiment ◽  
Low Cost ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
High Strength ◽  
Friction Stir ◽  
Tool Shape ◽  
Computational Fluid Dynamics Cfd

Abstract For the Friction stir welding (FSW) between aluminum and steel is important to fabricate vehicles with light weight and high strength for safety at low cost. For the fabrication of sound weld, it is necessary to control the material flow during FSW. In this study, the material flow during FSW was elucidated by numerical simulation by computational fluid dynamics (CFD) analysis and simulation experiment by transparent Poly-vinyle chloride (PVC) as simulant of aluminum and tracer material. Based on this material flow analysis, several shapes of welding tool were examined for control of material flow during FSW. Scroll shoulder is effective for enhancement of stirring zone by increasing material velocity around the probe. Flute and fine screw probe promote the material flow in depth and horizontal direction. The welding tool with scroll shoulder and flute and fine screw probe achieved sound weld with highest tensile strength of 120.4 MPa.

Experimentally Validated Thermo-Mechanically Coupled FE Simulations of Al/Mg Friction Stir Welded Joints

2013 ◽  
Author(s):  
A. H. Kheireddine ◽  
A. H. Ammouri ◽  
G. T. Kridli ◽  
R. F. Hamade
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Flow Patterns ◽  
Fe Model ◽  
Friction Stir ◽  
Flow Mixing ◽  
Dissimilar Friction Stir Welding ◽  
Daunting Task ◽  
Simulated Temperature ◽  
Deform 3D

Numerical simulations of the friction stir welding of dissimilar metal joints is a daunting task given the complex issues involved such as the flow mixing action and the phase transformations. In this work, a 3D thermo-mechanical FE model is developed to simulate the dissimilar friction stir welding (DFSW) of aluminum-magnesium bi-metallic joints. The model is built using a manufacturing-processing-specific FEM software package (DEFORM 3D). Suitable constitutive laws are implemented to describe flow stress for both welded constituents: Al and Mg. The flow patterns of the stirring action from the simulations were verified against flow patterns of steel shots reported from experiments published in the literature. Also, the simulated interface patterns were found to be in agreement with microscopic images of welded sections taken from reported experiments. Furthermore, simulated temperature profiles favorably compare with temperature measurements previously published in the literature. The numerical model output includes relevant results such as material flow and volume fractions throughout the joint but most importantly in the recrystallized stir zone.

scholarly journals Study of Temperature Distribution and Material Flow in Friction Stir Welding of AA6061-T6

2020 ◽  
Author(s):  
Manoj Kumar ◽  
Ramesh Kumar ◽  
Sachin D Kore
Keyword(s):  
Temperature Distribution ◽  
Rotational Speed ◽  
Material Flow ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
Tool Geometry ◽  
Low Velocity ◽  
Friction Stir ◽  
Tool Geometries ◽  
Velocity Magnitude

Abstract A fully-coupled 3-D model of FSW was developed for 4 mm plates of AA6061-T6 aluminum alloy based on the Finite Volume Method (FVM) in ANSYS Fluent 14.5 software. Two types of the model; one with the tool and another without tool was developed for different tool geometry and analysis was done for temperature distribution in the workpiece as well as in tool using system coupling for first model and workpiece only in later one. A parametric study was performed at different tool rotational speed regarding temperature distribution, and material flow analysis was carried out for all tool geometries at a single rotational speed. The material behaves differently when passes through the different tool and it was affected by thermal history, viscosity and strain rate for particular tool geometry. Temperature-dependent material properties and a user-defined function (UDF) code of viscosity have been incorporated in the model considering the workpiece as a non-Newtonian viscous fluid. A better material mixing observed in case of threaded pin geometry by using a steady-state laminar flow model. All tapered tool geometries were unable to mix material properly just below and around the pin tip due to very low-velocity magnitude in this region, which may lead to a kind of defect. An asymmetric temperature distribution observed in the workpiece and at higher rotational speed peak temperature observed higher in the workpiece, and the flow of heat was more in tool. Validation of the model was done by performing experiments.

scholarly journals Investigation into the Dissimilar Friction Stir Welding of AA5052 and AA6061 Aluminum Alloys Using Pin-Eccentric Stir Tool

Metals ◽  
2019 ◽  
Vol 9 (7) ◽  
pp. 718 ◽  
Author(s):  
Yu Chen ◽  
He Wang ◽  
Huaying Li ◽  
Xiaoyu Wang ◽  
Hua Ding ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Material Flow ◽  
Tensile Tests ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
Dissimilar Friction Stir Welding ◽  
Average Grain Size ◽  
Dislocation Strengthening ◽  
Onion Ring

Friction stir welding with different pin-eccentric stir tools (the pin eccentricities were 0, 0.4, and 0.8 mm, respectively) was successfully utilized for joining dissimilar aluminum alloys AA5052 and AA6061, and the influences of pin eccentricity on the microstructural evolution and mechanical properties of joints were investigated. The results showed that sound joints could be obtained by placing the hard AA6061 in the advancing side, while the welding heat input led to both the coarsening of strengthening precipitates and dynamic recrystallization and softening of the nugget zone (NZ). The application of pin eccentricity promoted the material flow in the NZ and enlarged the area of the “onion ring”. Furthermore, the average grain size and fraction of recrystallized grain in the NZ decreased as the pin eccentricity increased. All joints failed in the NZ during tensile tests, and the joint produced by the 0.8 mm-pin-eccentric stir tool performed the highest tensile strength due to the enhanced grain-boundary and dislocation strengthening.

scholarly journals Microtexture and Material Flow Analysis on Friction Stir Welded Materials

2010 ◽  
Vol 28 (5) ◽  
pp. 20-27
Author(s):  
Suk-Hoon Kang ◽  
Jae-Hyung Cho ◽  
Chang-Gil Lee ◽  
Sung-Joon Kim ◽  
Kyu-Hwan Oh ◽  
...  
Keyword(s):  
Material Flow ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
Friction Stir

scholarly journals Study of Temperature Distribution and Material Flow in Friction Stir Welding of AA6061-T6

2020 ◽  
Author(s):  
Manoj Kumar ◽  
Ramesh Kumar ◽  
Sachin D Kore
Keyword(s):  
Temperature Distribution ◽  
Rotational Speed ◽  
Material Flow ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
Tool Geometry ◽  
Low Velocity ◽  
Friction Stir ◽  
Tool Geometries ◽  
Velocity Magnitude

Abstract A fully-coupled 3-D model of FSW was developed for 4 mm plates of AA6061-T6 aluminum alloy based on the Finite Volume Method (FVM) in ANSYS Fluent 14.5 software. Two types of the model; one with the tool and another without tool was developed for different tool geometry and analysis was done for temperature distribution in the workpiece as well as in tool using system coupling for first model and workpiece only in later one. A parametric study was performed at different tool rotational speed regarding temperature distribution, and material flow analysis was carried out for all tool geometries at a single rotational speed. The material behaves differently when passes through the different tool and it was affected by thermal history, viscosity and strain rate for particular tool geometry. Temperature-dependent material properties and a user-defined function (UDF) code of viscosity have been incorporated in the model considering the workpiece as a non-Newtonian viscous fluid. A better material mixing observed in case of threaded pin geometry by using a steady-state laminar flow model. All tapered tool geometries were unable to mix material properly just below and around the pin tip due to very low-velocity magnitude in this region, which may lead to a kind of defect. An asymmetric temperature distribution observed in the workpiece and at higher rotational speed peak temperature observed higher in the workpiece, and the flow of heat was more in tool. Validation of the model was done by performing experiments.

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