SIMULATION ANALYSIS OF PEAK TEMPERATURE IN WELD ZONES DURING FRICTION STIR PROCESS

2015 ◽  
Vol 76 (8) ◽  
Author(s):  
M. Shamil Jaffarullah ◽  
Nur’Amirah Busu ◽  
Cheng Yee Low ◽  
J. B. Saedon ◽  
Armansyah Armansyah ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Rotational Speed ◽  
Simulation Analysis ◽  
Welding Process ◽  
Element Model ◽  
Traverse Speed ◽  
Peak Temperature ◽  
Friction Stir Process ◽  
Friction Stir

A three-dimensional (3D) finite element model was created to simulate the friction stir welding process of 6063-T5 aluminum alloy. The analysis studies the fundamental knowledge of FSW process with respect to temperature difference in material to be joined and to simulate the temperature distribution in the workpiece as a result of a Friction Stir Welding. The simulation uses HyperMesh and HyperView solver from Altair Hyperworks.  The simulation provides better understanding for the peak temperature distribution in the friction stir process. Two cases have (i) constant traverse speed, but varying been simulated rotational speed, and (ii) constant rotational speed, but varying traverse speeds. Simulation results show the peak temperatures increased when the traverse and rotational speeds were increased.

scholarly journals Temperature distribution of T- joint friction stir welding

2018 ◽  
Vol 7 (4) ◽  
pp. 2332
Author(s):  
Sadiq Aziz Hussein ◽  
Shaymaa Abdul Khader Al-Jumaili ◽  
Raed A. Mahmood
Keyword(s):  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Plate Thickness ◽  
Welding Process ◽  
Element Model ◽  
Thickness Effect ◽  
Joint Friction ◽  
Friction Stir ◽  
Welding Method ◽  
Structural Configurations

Friction stir welding is a reliable welding method; it can be employed to join different structural configurations. Joint types such as lap, butt and T have been successfully produced by this welding method. In this study, a trial has been made to numerically simulate the heat generation and temperature distribution during the welding process of a T-joint. The workpieces materials were hardened 5052 and tempered 7075 Al Alloys, each material was investigated separately. Different rotational and welding speeds were used, besides, the pin length was also varied to accommodate the investigation of the top plate thickness effect. A visco-plastic finite element model was adopted to investigate the effect of parameters ranges on the temperature distribution. The results showed that the temperature distribution of T-joint depends mainly on the material to be welded and rotational speed. Besides, increasing the pin length from 7 to 10 mm could significantly increase the resulted temperature by approximately 14%. Therefore, the thickness of the upper plates of the T-joint plays a significant role on the resulted process temperature.  

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

2020 ◽  
Vol 17 (4) ◽  
pp. 491-507 ◽  
Author(s):  
Nitin Panaskar ◽  
Ravi Prakash Terkar
Keyword(s):  
Experimental Data ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Central Composite

Purpose Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal. Design/methodology/approach In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated. Findings The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R2) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function. Originality/value Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

scholarly journals Experimental Investigation of Friction Stir Welding on 6061-T6 Aluminum Alloy using Taguchi-Based GRA

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1480
Author(s):  
Assefa Asmare ◽  
Raheem Al-Sabur ◽  
Eyob Messele
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Weight Ratio ◽  
Welding Process ◽  
Quality Criteria ◽  
Alloy Sheet ◽  
Friction Stir ◽  
Weld Joints

The use of aluminum alloys, nowadays, is swiftly growing from the prerequisite of producing higher strength to weight ratio. Lightweight components are crucial interest in most manufacturing sectors, especially in transportation, aviation, maritime, automotive, and others. Traditional available joining methods have an adverse effect on joining these lightweight engineering materials, increasing needs for new environmentally friendly joining methods. Hence, friction stir welding (FSW) is introduced. Friction stir welding is a relatively new welding process that can produce high-quality weld joints with a lightweight and low joining cost with no waste. This paper endeavors to deals with optimizing process parameters for quality criteria on tensile and hardness strengths. Samples were taken from a 5 mm 6061-T6 aluminum alloy sheet with butt joint configuration. Controlled process parameters tool profile, rotational speed and transverse speed were utilized. The process parameters are optimized making use of the combination of Grey relation analysis method and L9 orthogonal array. Mechanical properties of the weld joints are examined through tensile, hardness, and liquid penetrant tests at room temperature. From this research, rotational speed and traverse speed become significant parameters at a 99% confidence interval, and the joint efficiency reached 91.3%.

An Influence of Frictional Model on Temperature Distribution during a Friction Spot Stir Welding Process of Titanium Grade 2

2016 ◽  
Vol 687 ◽  
pp. 155-162
Author(s):  
Piotr Lacki ◽  
Zygmunt Kucharczyk ◽  
Tomasz Walasek
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Welding Process ◽  
Relative Speed ◽  
The Finite Element Method ◽  
Friction Stir ◽  
Temperature Distributions ◽  
Titanium Grade

In the paper, the influence of friction on temperature distribution in the friction spot stir welding process of titanium grade 2 is analysed. It is assumed that the friction coefficient may be a function of temperature or the relative speed of the contact areas. The finite element method is used in the numerical calculations. Temperature distributions and temperature versus time for the analysed friction coefficients are presented. The results also show that applying a proper frictional model is very essential for the sake of heat generation during friction stir welding.

scholarly journals Parametric Optimization of Friction Stir Welding Factors (FSWF) for Yellow Brass 405-20

2021 ◽  
Author(s):  
Syed Farhan Raza ◽  
Sarmad Ali Khan ◽  
Muhammad Salman Habib ◽  
Naveed Ahmed ◽  
Kashif Ishfaq ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Rotational Speed ◽  
Weld Zone ◽  
Tool Material ◽  
Traverse Speed ◽  
Weld Strength ◽  
Friction Stir Weld ◽  
Friction Stir ◽  
Wide Range ◽  
Percent Contribution

Abstract Friction stir welding (FSW) is a green, environmentally amicable, and solid-state joining technology. Industries are really interested in adopting FSW in its various applications e.g., automobile, aerospace, marine, construction, etc. FSW can successfully weld a wide range of materials (similar/dissimilar parent materials) including aluminum, copper, steel, different alloys from these materials, plastics, composites, and this material range is subjected to extension if FSW research efforts develop further in future. FSW of brass has already been accomplished by fewer researchers. In this research, yellow brass 405-20 is, therefore, welded with FSW that was never welded before. In this study, tool material utilized was M2 HSS that was also novel. Effect of two friction stir weld factors (FSWF), rotational speed (RS) and traverse speed (TS), was found on three output parameters i.e., weld temperature, weld strength and weld hardness. Weld temperature was found to be 63.72% of melting point of base metal. A significant improvement in friction stir weld strength (FSWS) was also measured that was found to be 82.78% of the base brass strength. Finally, weld hardness was measured which was found to be 87.80% of original brass hardness. Based on main effects of Anova Analysis, optimal FSW factors were found to be 1450 rpm and 60 mm/min resulting interestingly in maximum (max.)/optimal temperature, max./optimal weld strength, and minimum/optimal hardness. Rotational speed (RS) was found to be significant to affect the weld temperature only at the friction stir weld zone (FSWZ) with the highest percent contribution (PCR) of 65.69%. Transverse speed (TS) was found to be overall insignificant for affecting weld temperature, weld strength and hardness. However, PCR of transverse speed was found to be maximum for affecting weld strength as compared to its PCR towards both weld temperature and weld hardness. Error PCR was found to be the lowest for weld zone temperature, then for weld strength, and finally the highest for weld hardness. Interaction Plots (IPs) were also made for those FSWF which were found to be insignificant and to investigate any combined effect of FSWF on output parameters causing increased error PCR towards weld temperature, weld strength, and weld hardness.

scholarly journals Technology and equipment for friction stir preweld edge preparation

2021 ◽  
Vol 21 (2) ◽  
pp. 163-170
Author(s):  
Y. G. Lyudmirsky ◽  
А. N. Soloviev ◽  
М. V. Soltovets ◽  
R. R. Kotlyshev ◽  
I. V. Mironov ◽  
...  
Keyword(s):  
Finite Element ◽  
Theoretical Model ◽  
Friction Stir Welding ◽  
Geometric Model ◽  
Three Dimensional ◽  
Welding Process ◽  
Element Model ◽  
Element Mesh ◽  
Laboratory Equipment ◽  
Friction Stir

Introduction. Friction stir welding is widely used due to certain advantages of this method. Factors that reduce the strength of joints made of high-strength aluminum alloys are considered. When welding flat sheets, an effective way to increase the strength of the weld is edge thickening. The paper proposes a method for such thickening. A device is developed, calculations and experiments are carried out. Materials and Methods. Laboratory equipment has been developed to provide simultaneous thickening of two edges to be welded. The main component of this equipment is a steel roller, which is rolled along the edges of two blanks and thickens them due to plastic deformation. The same setup can be used for the friction stir welding process. To calculate the geometry of the thickened edges and the parameters of the deforming roller depending on the value of the edge settlement, a mathematical model based on the contact problem for elastic (roller) and elastoplastic (blank) bodies with a bilinear hardening law has been developed. A three-dimensional simplified geometric model of the facility with account of its symmetry has been constructed. On the contact surfaces, special contact finite elements were selected and the finite element mesh was refined. The numerical implementation of the model was carried out in the ANSYS package. Results. The theoretical model provides assessing the stress-strain state of interacting elements. On the basis of the developed finite element model, the parameters of the thickened edges are calculated, and the geometry of the thickened edges is defined. Using the developed laboratory equipment, full-scale experiments on thickening the edges of the blanks were carried out. The experimental results confirm the adequacy of the developed theoretical model and calculations based on it. The possibility of adjusting the size of the thickened edges is shown.Discussion and Conclusion. A technology for obtaining thickened edges in places of welds is proposed. It will reduce the metal consumption of structures and ensure the bearing capacity of welded joints not lower than similar characteristics of the base metal. A theoretical model of the process is developed, and a numerical experiment providing the selection of the process parameters is carried out. 

scholarly journals An Experimental Test and Optimization of Friction Stir Welding Process for AA6082 By using GRA

2020 ◽  
Vol 9 (6) ◽  
pp. 740-744
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Axial Force ◽  
Welding Process ◽  
Traverse Speed ◽  
Test Plate ◽  
Friction Stir ◽  
Fourth Sample ◽  
Grey Relational Grade ◽  
Grey Relational

Friction stir welding (FSW) is a type of joining process, it uses solid state welding method, also it is widely used in same type and different types of welding like Al, Mg, Cu, Ti, and their alloys. In this study, friction stir welding of two aluminum alloys AA6082 is done with many sets of tool rotation speed, feed and axial force. In this experimental work FSW process was carried out for AA 6082 and optimization of that FSW process parameters were find out for maximum tensile strength values. Taguchi’s L4 orthogonal array was utilized for three parameters – tool rotational speed (TRS), traverse speed (TS), and axial force (AXF) with two levels. Several optimization was carried out with Taguchi method of grey relational tests. During the investigation obtained highest tensile strength value fourth sample 60.887 N/mm2 and lowest hardness strength value second sample 31HRB and bead appearance found very best surface occurred fourth test plates at the same time angle distortion observed very fine in the fourth test plate. The result was calculated for both ultimate tensile strength and hardness value. The expected grey relational grade was shifted from 0.704 to 0.792, it was the highest value received throughout this experimental results. It was mentioned that the multi-responses of FSW process was improved with this method.

scholarly journals Investigation of mechanical and micro structural properties of ST14 steel sheet joints by friction stir welding process

2020 ◽  
Author(s):  
Mahmoud Afshari ◽  
Ehsan Salahshour Rad ◽  
Hossein Norozi Foroushani ◽  
Iraj Sattari Far
Keyword(s):  
Friction Stir Welding ◽  
Tungsten Carbide ◽  
Rotational Speed ◽  
Welding Process ◽  
Linear Motion ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Motion Speed ◽  
St14 Steel ◽  
Carbide Particles

Abstract High strength and ductility are some of reasons that make ST14 steel one of the most widely used steels in automotive and aerospace industries. FSW is one of the new methods of solid-state welding that is proposed as a method with desirable mechanical properties.In this study, mechanical and microstructural properties of 1.5mm thick ST14 steel sheets were investigated in the friction stir welding process. The results showed that the welded specimen with rotational speed of 800 rpm and linear motion speed of 80 mm/min had the highest tensile strength of 305MPa. In addition, results of metallographic test showed that the sample with 1000 rpm rotational speed and 50 mm/min linear motion speed had the highest heat input to the piece, and therefore the tungsten carbide particles were separated from the instrument and entered the stirred zone. Also the results of micro hardness test showed that in the welded specimen with rotational speed of 1000 rpm and linear motion speed of 50 mm/min, hardness increased to 115H1 HV in the stirred zone, which is higher than hardness of other samples in same region. It can be claimed that tungsten carbide particles are present in this area.

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