scholarly journals FSW Numerical Simulation of Aluminium Plates by Sysweld - Part I

2016 ◽  
Vol 66 (1) ◽  
pp. 47-52 ◽  
Author(s):  
Roland Jančo ◽  
Ladislav Écsi ◽  
Pavel Élesztős
Keyword(s):  
Numerical Simulation ◽  
Material Flow ◽  
Fluid Simulation ◽  
Stress And Strain ◽  
The Finite Element Method ◽  
Friction Stir ◽  
Simulation Process ◽  
Potential Applications ◽  
Solid State Joining ◽  
Physical Quantities

AbstractFriction Stir Welding (FSW) is one of the most effective solid state joining processes and it has numerous potential applications in many industries. The simulation process can provide the evolution of physical quantities such as temperature, metallurgical phase proportions, stress and strain which can be easily measured during welding. The numerical modelling requires the modelling of a complex interaction between thermal, metallurgical and mechanical phenomena. The aim of this paper is to describe the thermal-fluid simulation of FSW using the finite element method. In the theoretical part of the paper heating is provided by the material flow and contact condition between the tool and the welded material. The thermal-fluid results from the numerical simulation for aluminium alloy using SYSWELD are also presented in this paper.

scholarly journals FSW Numerical Simulation of Aluminium Plates by SYSWELD - Part II

2016 ◽  
Vol 66 (2) ◽  
pp. 29-36 ◽  
Author(s):  
Roland Jančo ◽  
Ladislav Écsi ◽  
Pavel Élesztős
Keyword(s):  
Numerical Simulation ◽  
Material Flow ◽  
Complex Interaction ◽  
Fluid Simulation ◽  
Stress And Strain ◽  
The Finite Element Method ◽  
Friction Stir ◽  
Simulation Process ◽  
Potential Applications ◽  
Solid State Joining

Abstract Friction Stir Welding (FSW) is one of the most effective solid state joining processes and has numerous potential applications in many industries. The simulation process can provide the evolution of physicals quantities such as temperature, metallurgical phase proportions, stress and strain which can be easily measured during welding. The numerical modelling requires the modelling of the complex interaction between thermal, metallurgical and mechanical phenomena. The aim of this paper is to describe the thermal-fluid simulation of FSW using the finite element method. In the theoretical part of paper heating is provided by the material flow and contact condition between the tool and the welded material. Thermal-mechanical results from the numerical simulation using SYSWELD are also presented for aluminium alloy.

Numerical Analysis of Multi-Field Coupled Phenomena in Friction Stir Welding and Applications

2014 ◽  
Vol 783-786 ◽  
pp. 1794-1807
Author(s):  
Qing Yu Shi ◽  
Gao Qiang Chen ◽  
Xi Bo Wang ◽  
Xu Kang
Keyword(s):  
Numerical Simulation ◽  
Friction Stir Welding ◽  
Heat Generation ◽  
Material Flow ◽  
Metal Flow ◽  
Friction Stir ◽  
Rate Dependent ◽  
Potential Applications ◽  
Complex Phenomena ◽  
Fsw Parameters

Friction stir welding (FSW) is an advanced solid state joining technology, which was invented by TWI in 1991. During the process, large amount of heat is generated due to the friction between the tool and the material. As a result, the metal around the tool is softened as the temperature rises, and significant plastic flow occurs. So FSW is a complex process with multi-field coupled phenomena. Material flow plays a central role in FSW. But it is still difficult to reveal the material flow regime and joining mechanism during FSW process. Numerical simulation is a powerful tool for investigating the metal-flow-related complex phenomena during FSW. Meanwhile, numerical simulation could also help to optimize FSW tool design and FSW parameters. In this paper, we review the recent development in simulation of material flow during FSW. Then, the important issues in modeling multi field coupled phenomena during FSW are summarized, which include the heat generation mechanism, the temperature and strain rate dependent material’s behavior, and the interaction between tool and material. Finally, a comprehensive simulation model is presented, which enables advanced study on the coupled phenomena of heat generation, temperature distribution, material flow, and defects formation. This model has shown potential applications in simulating the relation between the transport of material and the macrostructure formation or defects formation. In spite of these progresses, simulation of material flow during FSW still need quite a lot of researches to fulfill industry requirement.

Effects of different cooling conditions on friction stir processing of A356 alloy: Numerical modeling and experiment

2021 ◽  
pp. 095440622110456
Author(s):  
Mostafa Akbari ◽  
Parviz Asadi
Keyword(s):  
Wear Resistance ◽  
Temperature Distribution ◽  
Simulation Model ◽  
Material Flow ◽  
A356 Alloy ◽  
Experimental Investigations ◽  
Air Cooling ◽  
The Finite Element Method ◽  
Friction Stir ◽  
Good Agreement

In the present work, the effects of in-process cooling are investigated on the material flow, temperature distribution, axial force, wear resistance, and microstructural and mechanical properties of friction stir processed (FSPed) Al-Si aluminum alloy. The finite element method (FEM) was developed for modeling the process, based on the eulerian-lagrangian technique, and then verified by the experimental force and temperature histories. Next, the material flow and temperature distribution during the friction stir process (FSP) with in-process cooling under different conditions were considered. After that, the experimental investigations, including the optical microscopy, hardness, and wear tests, were conducted. Finally, the stir zone (SZ) shape obtained by experiments and simulation model were compared for the FSPed samples without cooling and with air cooling. The material flow achievements reveal that using a coolant affects the material flow in the pin-driven zone more significantly than in the shoulder-driven zone, leading the SZ to change from the basin shape into the V shape. The SZ shapes obtained from the experiments and the simulation model show a good agreement between the shapes of the samples FSPed without cooling and with air cooling. Moreover, experimental results showed that using in-process cooling reduces Si particles' size and thus significantly increases the hardness and wear resistance. The Si particles size is reduced from 10 μm in the base metal to 2.6 μm and 2 μm in the air-cooled and water-cooled samples. Consequently, the wear mass loss reduced almost 28% and 40%, and hardness increased almost 35% and 80% for the air-cooled and water-cooled samples compared to the processed samples without coolant.

scholarly journals Material flow in Friction Stir Welding

2008 ◽  
Vol 14 (S3) ◽  
pp. 87-90 ◽  
Author(s):  
C. Leitão ◽  
R.M. Leal ◽  
D.M. Rodrigues ◽  
P. Vilaça ◽  
A. Loureiro
Keyword(s):  
Plastic Deformation ◽  
Friction Stir Welding ◽  
Automotive Industry ◽  
Aluminium Alloys ◽  
Material Flow ◽  
Dissimilar Materials ◽  
Tool Geometry ◽  
X Ray ◽  
Friction Stir ◽  
Solid State Joining

Friction stir welding (FSW) is a solid-state joining technique initially developed for aluminium alloys. The heat generated by a rotating tool softens the material in the vicinity of the tool. The material undergoes intense plastic deformation following quite complex paths around the tool, depending on the tool geometry, process parameters and material to be welded. The comprehension of the material flow is essential to prevent voids and other internal defects which may form during welding. Several techniques have been used for tracking material flow during FSW such as metallography, the use of a marker material as a tracer or the flow visualization by FSW of dissimilar materials or even the X-ray and computer tomography. Some of these techniques are useless in the analysis of welds in homogenous materials or welds between materials of the same group. The aim of this investigation is tracking the material flow in FSW between 1mm thick sheets in aluminium alloys AA 5182-H111 and AA 6016-T4, currently used in automotive industry.

scholarly journals Numerical Modelling and Simulation of Road Crash Tests with the use of Advanced CAD/CAE Systems / Modelowanie Numeryczne I Symulacja Drogowych Testów Zderzeniowych Z Wykorzystaniem Zaawansowanych Systemów CAD/CAE

2012 ◽  
Vol 23 (1) ◽  
pp. 95-108 ◽  
Author(s):  
Tadeusz Niezgoda ◽  
Wiesław Barnat ◽  
Paweł Dziewulski ◽  
Andrzej Kiczko
Keyword(s):  
Numerical Simulation ◽  
Energy Consumption ◽  
Numerical Modelling ◽  
Low Cost ◽  
Stress And Strain ◽  
Computing Systems ◽  
Strain Fields ◽  
Simulation Process ◽  
Road Crash ◽  
Crash Tests

Abstract The paper presents the methodology of numerical modelling of road crash tests based on the selected vehicle-road barrier system using the possibilities of modern CAD /CAE computing systems for a numerical simulation process of the collision. Owing to these systems, thorough analysis of the process of collision, including the analysis of the stress and strain fields and energy consumption in the tested systems, is possible. It is possible to design and redesign virtually the barriers at a relatively low cost.

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