Thermal Analysis of Friction Stir Welding Process Under Different Control and Energy Parameters

2015 ◽  
Author(s):  
Dalong Yi ◽  
Hui Zhang
Keyword(s):  
Heat Transfer ◽  
Temperature Distribution ◽  
Thermal Condition ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Traverse Speed ◽  
Transfer Model ◽  
Welding Condition ◽  
Plunge Depth ◽  
Friction Stir

Friction Sir Welding (FSW) process is a solid state welding technology which is widely used in manufacturing field for joints of many types of same or dissimilar materials such as aluminum alloys, magnesium alloys and steels and so on. In addition, FSW process is also a complex process associated with heat transfer, plastic deformation, grain recrystallization and material property changing phenomenon. It is commonly known that the thermal condition or the temperature distribution of space and time is important to the final welding condition. However, due to the limitation of experiment measurement and the unfinished work of numerical heat transfer model, the relationship between thermal condition and control parameters still remains a question. In this work, a new numerical model based on energy analysis and finite element method is built to calculate the thermal field of FSW process. The energy generation due to plunge depth and the converting coefficient of friction energy to heat are considered in the model. The effects of energy distribution of both sides, energy efficiency of friction, plunge depth, normal force, traverse speed and rotation speed on the temperature distribution of FSW process are investigated.

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.

Numerical Analysis of In-Process Heat Transfer and Material Flow During Dissimilar Friction Stir Welding Process

2019 ◽  
Author(s):  
Gaoqiang Chen ◽  
Xun Liu ◽  
Qingyu Shi
Keyword(s):  
Heat Transfer ◽  
Friction Stir Welding ◽  
Material Flow ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Coupling Behavior ◽  
Dissimilar Friction Stir Welding ◽  
Computational Fluid Dynamics Cfd ◽  
Process Heat

Abstract Friction stir welding (FSW) has been successfully applied to join dissimilar materials in engineering applications. Fundamental understanding on the underlying physical principles of the dissimilar FSW process is generally required to achieve strong and reliable joints. In this study, we aim to develop a theoretical and numerical model based on computational fluid dynamics (CFD) in order to analyze the in-process heat transfer and material flow during the dissimilar FSW of aluminum and steel. The model describes the coupling behavior between the material distribution, thermal-mechanical properties, interfacial friction, heat generation and transfer. To account for the different material behaviors in stirring zone, a VOF-based approach is adopted. In this paper, preliminary numerical simulation is conducted. Simulation results show that the current modeling approach has the capability to capture the material mixing during the dissimilar FSW of aluminum and steel. The predicted temperature field is shown to be asymmetrical, which is attributed to the different properties of aluminum and steel. The predicted thermal history agrees with the experimental measurements in the literature.

scholarly journals Effects of the FSW Parameters on Microstructure and Electrical Properties in Al 6061-T6- Cu C11000 Plate Joints

Crystals ◽  
2020 ◽  
Vol 11 (1) ◽  
pp. 21
Author(s):  
Daniel García-Navarro ◽  
Juan Carlos Ortiz-Cuellar ◽  
Jesús Salvador Galindo-Valdés ◽  
Josué Gómez-Casas ◽  
Carlos Rodrigo Muñiz-Valdez ◽  
...  
Keyword(s):  
Electrical Resistivity ◽  
Friction Stir Welding ◽  
Electrical Properties ◽  
Weld Zone ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Traverse Speed ◽  
Friction Stir ◽  
Fsw Parameters ◽  
Pure Cu

Friction Stir Welding (FSW) is a feasible welding process to join dissimilar materials due to its solid-state nature. In this study the FSW of 6061-T6 aluminum with pure Cu plates was performed with the objective of evaluating the effects of the FSW parameters on the microstructure and electrical properties. The processing parameters (rotational and traverse speeds) were established to reduce the common defects in the friction-stir welding process. Therefore, the obtained results validated the better mechanical properties and a smaller increase of the electrical resistivity. The rotational speeds used were of 1000, 1150, and 1300 rpm, and the traverse speeds of 20, 40, and 60 mm/min, with the purpose of varying the heat input of the process. The microstructural characterization revealed the presence of a mixture of aluminum and copper into the weld zone, along with copper particles and the formation of intermetallic compounds. It was found that the electrical resistivity of the joints ranged from 0.029 to 0.036 μΩ. The highest electrical resistivity values were obtained at the lowest traverse speed (20 mm/min) and the lowest resistivity values were obtained at highest traverse speed (60 mm/min).

Influence of Friction Stir Welding Process on the Weld Formation and Tensile Strength of Titanium and Aluminum Dissimilar Alloys Welded Joint

2011 ◽  
Vol 189-193 ◽  
pp. 3266-3269 ◽  
Author(s):  
Yu Hua Chen ◽  
Peng Wei ◽  
Quan Ni ◽  
Li Ming Ke
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Cross Section ◽  
Welded Joint ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Influence Of Process Parameters ◽  
Friction Stir ◽  
Dissimilar Alloys ◽  
Titanium Aluminum

Titanium alloy TC1 and Aluminum alloy LF6 were jointed by friction stir welding (FSW), and the influence of process parameters on formation of weld surface, cross-section morphology and tensile strength were studied. The results show that, Titanium and Aluminum dissimilar alloy is difficult to be joined by FSW, and some defects such as cracks and grooves are easy to occur. When the rotational speed of stir head(n) is 750r/min and 950r/min, the welding speed(v) is 118mm/min or 150mm/min, a good formation of weld surface can be obtained, but the bonding of titanium/aluminum interface in the cross-section of weld joint is bad when n is 750r/min which results in a low strength joint. When n is 950r/min and v is 118mm/min，the strength of the FSW joint of Titanium/Aluminum dissimilar materials is 131MPa which is the highest．

scholarly journals An analytical method to estimate temperature distribution of typical radiant floor cooling systems with internal heat radiation

2021 ◽  
pp. 014459872199800
Author(s):  
Xiaolong Wang ◽  
Wenke Zhang ◽  
Qingqing Li ◽  
Zhenqiang Wei ◽  
Wenjun Lei ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Temperature Distribution ◽  
Internal Heat ◽  
Single Layer ◽  
Heat Radiation ◽  
Transfer Model ◽  
Cooling Systems ◽  
Average Temperature ◽  
Floor Surface ◽  
Floor Structure

Radiant floor cooling systems are increasingly used in practice. The temperature distribution on the floor surface and inside the floor structure, especially the minimum and average temperature of floor surface, determines the thermal performance of radiant floor systems. A good temperature distribution of the floor structure is very important to prevent occupant discomfort and avoid possible condensation in summer cooling. In this study, based on the heat transfer model of the single-layer homogeneous floor structure when there is no internal heat radiation in the room, this paper proposes a heat transfer model of single-layer floor radiant cooling systems when the room has internal heat radiation. Using separation variable methods, an analytical solution was developed to estimate temperature distribution of typical radiant floor cooling systems with internal heat radiation, which can be used to calculate the minimum temperature and the average temperature of typical composite floor structure. The analytical solution was validated by experiments. The values of the measured experiments are in a good agreement with the calculations. The absolute error between the calculated and the measured floor surface temperatures was within 0.45°C. The maximum relative error was within 2.31%. Prove that this model can be accepted. The proposed method can be utilized to calculate the cooling capacity of a typical multi-layer composite floor and will be developed in the future study for design of a typical radiant floor cooling system.

Modelling of Thermal Quantities for Quick Process Assessment and Process Capability Space Refinement at an Early Design Phase During Laser Welding

2021 ◽  
Author(s):  
Anand Mohan ◽  
Dariusz Ceglarek ◽  
Michael Auinger
Keyword(s):  
Heat Transfer ◽  
Laser Welding ◽  
Cooling Rate ◽  
Process Parameters ◽  
Thermal Cycle ◽  
Welding Process ◽  
Process Capability ◽  
Peak Temperature ◽  
Transfer Model ◽  
Process Assessment

Abstract This research aims at understanding the impact of welding process parameters and beam oscillation on the weld thermal cycle during laser welding. A three-dimensional heat transfer model is developed to simulate the welding process, based on the finite element (FE) method. The calculated thermal cycle and weld morphology are in good agreement with experimental results from literature. By utilizing the developed heat transfer model, the effect of welding process parameters such as heat source power, welding speed, radius of oscillation, and frequency of oscillation on the intermediate performance indicators (IPIs) such as peak temperature, heat-affected zone volume (HAZ), and cooling rate is quantified. Parametric contour maps for peak temperature, HAZ volume, and cooling rate are developed for the estimation of the process capability space. An integrated approach for rapid process assessment, process capability space refinement, based on IPIs is proposed. The process capability space will guide the identification of the initial welding process parameters window and help in reducing the number of experiments required by refining the feasible region of process parameters based on the interactions with the IPIs. Here, the peak temperature indicates the mode of welding performed while the HAZ volume and cooling rate are weld quality indicators. The regression relationship between the welding process parameters and the IPIs is established for quick estimation of IPIs to replace time-consuming numerical simulations. The proposed approach provides a unique ability to simulate the laser welding process and provides a robust range of process parameters.

scholarly journals Analysis of the influence of position of welding materials on the FSW seams properties for three dissimilar aluminium alloy

2018 ◽  
Vol 178 ◽  
pp. 03003 ◽  
Author(s):  
Ana Bosneag ◽  
Marius Adrian Constantin ◽  
Eduard Niţu ◽  
Monica Iordache
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Arc Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Workpiece Material ◽  
Friction Stir ◽  
Welding Joints ◽  
Welding Materials

Friction Stir Welding, abbreviated FSW is a new and innovative welding process. This welding process is increasingly required, more than traditional arc welding, in industrial environment such us: aeronautics, shipbuilding, aerospace, automotive, railways, general fabrication, nuclear, military, robotics and computers. FSW, more than traditional arc welding, have a lot of advantages, such us the following: it uses a non-consumable tool, realise the welding process without melting the workpiece material, can be realised in all positions (no weld pool), results of good mechanical properties, can use dissimilar materials and have a low environmental impact. This paper presents the results of experimental investigation of friction stir welding joints to three dissimilar aluminium alloy AA2024, AA6061 and AA7075. For experimenting the value of the input process parameters, the rotation speed and advancing speed were kept the same and the position of plates was variable. The exit date recorded in the time of process and after this, will be compared between them and the influence of position of plate will be identified on the welding seams properties and the best position of plates for this process parameters and materials.

Study on Effective Radial Thermal Conductivity of Gas Flow through a Methanol Reactor

2015 ◽  
Vol 13 (1) ◽  
pp. 103-112 ◽  
Author(s):  
Kun Lei ◽  
Hongfang Ma ◽  
Haitao Zhang ◽  
Weiyong Ying ◽  
Dingye Fang
Keyword(s):  
Heat Transfer ◽  
Thermal Conductivity ◽  
Reynolds Number ◽  
Temperature Distribution ◽  
Large Scale ◽  
Gas Flow ◽  
Fixed Bed ◽  
Heat Transfer Model ◽  
Transfer Model ◽  
Particle Reynolds Number

Abstract The heat conduction performance of the methanol synthesis reactor is significant for the development of large-scale methanol production. The present work has measured the temperature distribution in the fixed bed at air volumetric flow rate 2.4–7 m3 · h−1, inlet air temperature 160–200°C and heating tube temperature 210–270°C. The effective radial thermal conductivity and effective wall heat transfer coefficient were derived based on the steady-state measurements and the two-dimensional heat transfer model. A correlation was proposed based on the experimental data, which related well the Nusselt number and the effective radial thermal conductivity to the particle Reynolds number ranging from 59.2 to 175.8. The heat transfer model combined with the correlation was used to calculate the temperature profiles. A comparison with the predicated temperature and the measurements was illustrated and the results showed that the predication agreed very well with the experimental results. All the absolute values of the relative errors were less than 10%, and the model was verified by experiments. Comparing the correlations of both this work with previously published showed that there are considerable discrepancies among them due to different experimental conditions. The influence of the particle Reynolds number on the temperature distribution inside the bed was also discussed and it was shown that improving particle Reynolds number contributed to enhance heat transfer in the fixed bed.

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