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.

scholarly journals Iranian Steel Industry: Domination of Dispersed Direct Reduction Plants in an Inefficient Value Chain and a Droughty Environment

2021 ◽  
Author(s):  
Sepehr Ghazinoory ◽  
Mehdi Fatemi ◽  
Abolfazl Adab
Keyword(s):  
Value Chain ◽  
Steel Industry ◽  
Material Flow ◽  
Steel Ingot ◽  
Direct Reduction ◽  
Low Cost ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
Added Value ◽  
Easy Access

Abstract Iran has a great advantage in the development of the steel industry due to its access to mineral resources and energy, extensive consumer market, and low-cost labor. In this article, the Iranian steel value chain in 2014-2016 is studied using the value chain analysis and material flow analysis. Accordingly, based on the statistics related to the input and output of each echelon in the chain, the material flow is analyzed throughout the value chain. Then the total added value from the chain, the share of different stages, and the various costs in each echelon are calculated. According to the research findings, weakness in the development of transportation infrastructure and poor geographical distribution of value chain units has led to the deviation of production from nominal capacity and frequent imports/exports throughout the chain. On the other hand, the upstream industries have a permanent advantage that deeply roots in easy access to the minerals and lower costs in transportation and energy. Finally, the pricing of intermediate products based on the ratio of steel ingot prices is criticized, while wage conversion and commodity purification contracts are proposed as possible solutions for the reduction of overhead costs.

scholarly journals Numerical Studies on Temperature and Material Flow During Friction Stir Welding using Different Tool Pin Profiles

2021 ◽  
Vol 83 (1) ◽  
pp. 91-104
Author(s):  
M. D. Bindu ◽  
P. S. Tide ◽  
A. B. Bhasi
Keyword(s):  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Material Flow ◽  
Three Dimensional ◽  
Friction Stir ◽  
Specific Strength ◽  
Numerical Studies ◽  
Computational Fluid Dynamics Cfd ◽  
Tool Pin ◽  
Metal Hardness

A three dimensional computational fluid dynamics (CFD) model has been developed to study the effect of tool pin profile on the material flow and temperature development in friction stir welding (FSW) of high specific strength AA 7068 alloy. Numerical simulations were carried out using a RNG k-e turbulence model. Three tool pin profiles, viz. cylindrical, conical and straight cylindrical threaded were considered for the simulation. The temperature distribution and material flow pattern obtained from the simulation were compared for different pin profiles. Simulation results predicted Temperature distribution and material maxing was better in straight cylindrical tapered thread pin welds. Weld joints were fabricated using the straight cylindrical threaded pin with the same parametric combinations as in the simulation. Peak temperature measured in the experiment was less than that obtained by simulation. Hardness measurements taken at different weld regions has showed that about 71% of that of the base metal hardness is obtained with the threaded tool pin. The microstructure study revealed a defect free weld joint. Precipitates distributed in the microstructure indicate sufficient heat input to join the material without dissolving precipitates. The developed numerical model is helpful in optimising FSW process parameters.

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

2021 ◽  
Author(s):  
Toshiaki Yasui ◽  
Yuki Ogura ◽  
Xu Huilin ◽  
Farrah Najwa ◽  
Daichi Sugimoto ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Friction Stir ◽  
Tool Shape

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 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.

scholarly journals Study of Temperature Distribution and Material Flow for different pin profile 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 the 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 the 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 tools 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 was observed in the 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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