scholarly journals 3D modeling of material flow and temperature in Friction Stir Welding

2009 ◽  
Vol 14 (3) ◽  
pp. 248-256 ◽  
Author(s):  
Diego Santiago ◽  
Santiago Urquiza ◽  
Guillermo Lombera ◽  
Luis de Vedia
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Frictional Heating ◽  
Welding Process ◽  
Experimental Tests ◽  
General Purpose ◽  
Friction Stir ◽  
Welding Equipment ◽  
Reducing Costs ◽  
Visualization Techniques

The process of Friction Stir Welding (FSW) is a welding method developed by the "The Welding Institute" (TWI) of England in 1991. The welding equipment consists of a tool that rotates and progresses along the joint of two restrained sheets. The joint is produced by frictional heating which causes the softening of both components into a viscous-plastic condition and also by the resultant flow between the sheets to be joined. Numerical Modeling of the process can provide realistic prediction of the main variables of the process, reducing the number of experimental tests, thus accelerating the design processes while reducing costs and optimizing the involved technological variables. In this study the friction stir welding process is modeled using a general purpose finite element based program, reproducing the material thermal map and the corresponding mass flow. Numerical thermal results are compared against experimental thermographic maps and numerical material flow results are compared with material flow visualization techniques, with acceptable concordance.

Thermo-Mechanical Modelling of Friction Stir Welding Process

2013 ◽  
Vol 774-776 ◽  
pp. 1155-1159 ◽  
Author(s):  
Xiao Cong He
Keyword(s):  
Finite Element Analysis ◽  
Friction Stir Welding ◽  
Mechanical Behaviour ◽  
Material Flow ◽  
Welding Process ◽  
Element Analysis ◽  
Friction Stir ◽  
Mechanical Modelling ◽  
Major Factors ◽  
Realistic Prediction

Friction stir welding (FSW) is a solid-state welding process where no gross melting of the material being welded takes place. Numerical modelling of the FSW process can provide realistic prediction of the thermo-mechanical behaviour of the process. Latest literature relating to finite element analysis (FEA) of thermo-mechanical behaviour of FSW process is reviewed in this paper. The recent development in thermo-mechanical modelling of FSW process is described with particular reference to two major factors that influence the performance of FSW joints: material flow and temperature distribution. The main thermo-mechanical modelling used in FSW process are discussed and illustrated with brief case studies from the literature.

A Finite Element Model for the Prediction of Chip Formation and Surface Morphology in Friction Stir Welding Process

2021 ◽  
pp. 1-21
Author(s):  
Debtanay Das ◽  
Swarup Bag ◽  
Sukhomay Pal ◽  
M. Ruhul Amin
Keyword(s):  
Finite Element ◽  
Friction Stir Welding ◽  
Surface Morphology ◽  
Chip Formation ◽  
Material Flow ◽  
Welding Process ◽  
Measured Temperature ◽  
Material Loss ◽  
Friction Stir ◽  
Mass Scaling

Abstract Friction stir welding (FSW) is widely recognized green manufacturing process capable of producing good quality welded joints at temperature lower than the melting point. However, most of the works is focused on to the establishment of the process parameters for a defect-free joint. There is a lack to understand the formation of defects from physical basis and visualization of the same, which is otherwise difficult to predict by means of simple experiments. The conventional models do not predict chip formation and surface morphology by accounting the material loss during the process. Hence, a 3D finite element based thermo-mechanical model is developed following Coupled Eulerian-Lagrangian (CEL) approach to understand surface morphology by triggering material flow associated with tool-material interaction. In the present quasi-static analysis, the mass scaling factor is explored to make the model computationally feasible by varying the FSW parameter of plunge depth. The simulated results are validated with experimentally measured temperature and surface morphology. In CEL approach, the material flow out of the workpiece enables the visualization of the chip formation, whereas small deformation predict the surface quality of the joint.

Numerical Study of the Tool Rake Angle Effect on the Material Flow in Friction Stir Welding Process

2007 ◽  
Author(s):  
Hosein Atharifar ◽  
Radovan Kovacevic
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Numerical Study ◽  
Welding Process ◽  
Rake Angle ◽  
Heat Transfer Analysis ◽  
Tool Geometry ◽  
Friction Stir ◽  
Tool Pin ◽  
Welding Processes

Minimizing consumed energy in friction stir welding (FSW) is one of the prominent considerations in the process development. Modifications of the FSW tool geometry might be categorized as the initial attempt to achieve a minimum FSW effort. Advanced tool pin and shoulder features as well as a low-conductive backing plate, high-conductive FSW tools equipped with cooling fins, and single or multi-step welding processes are all carried out to achieve a flawless weld with reduced welding effort. The outcomes of these attempts are considerable, primarily when the tool pin traditional designs are replaced with threaded, Trifiute or Trivex geometries. Nevertheless, the problem remains as to how an inclined tool affects the material flow characteristics and the loads applied to the tool. It is experimentally proven that a positive rake angle facilitates the traverse motion of the FSW tool; however, few computational evidences were provided. In this study, numerical material flow and heat transfer analysis are carried out for the presumed tool rake angle ranging from −4° to 4°. Afterwards, the effects of the tool rake angle to the dynamic pressure distribution, strain-rates, and velocity profiles are numerically computed. Furthermore, coefficients of drag, lift, and side force and moment applied to the tool from the visco-plastic material region are computed for each of the tool rake angles. Eventually, this paper confirms that the rake angle dramatically affects the magnitude of the loads applied to the FSW tool, and the developed advanced numerical model might be used to find optimum tool rake angle for other aluminum alloys.

Study of Heat Dissipation Generated in Tool Designed for Friction Stir Welding Process (FSW)

2015 ◽  
Vol 1125 ◽  
pp. 171-175
Author(s):  
G. Paramo ◽  
A. Benitez
Keyword(s):  
Friction Stir Welding ◽  
Heat Dissipation ◽  
Welding Process ◽  
Experimental Tests ◽  
Tool Design ◽  
Milling Machine ◽  
Technical Parameters ◽  
Friction Stir ◽  
Heat Dispersion ◽  
The Right

Friction stir welding (FSW) is an alternative method of joining materials with low melting point, patented in 1991 by the American Welding Institute (UK). This method uses the heat generated by mechanical friction between two moving parts, one is the tool rotates and is fastened on the spindle of a conventional milling machine and the other is the part that is attached and is gagged on the bed of the machine. Among the variables identified as the most important for a successful run of the process are the revolutions per minute (RPM) at which the tool rotates, the speed advance at which the workpiece and the tool design as such moves [1]. In this paper the design of several tools applied to FSW process is studied in specific dissipation of heat generated by mechanical friction between the parts, its relation to tool design and qualities of successful meetings is presented, the methodology to achieve this goal was first identify the possible and applicable materials for the tools, second his respective designs to ensure the right function for operation, and finally define FSW technical parameters (RPM, Head angle, speed advance) for experimental tests. The findings and conclusions attribute a novel analysis in the design of tools for this innovative manufacturing process, in the analysis of the results obtained for each of the assemblies experimentation it was discovered that the use of rings at the parts are not decisive for a good weld even heat dispersion is not good.

Study on the effects of tool tile angle, offset and plunge depth on friction stir welding of poly(methyl methacrylate) T-joint

2019 ◽  
Vol 234 (4) ◽  
pp. 773-787 ◽  
Author(s):  
Arameh Eyvazian ◽  
Abdel Magid Hamouda ◽  
Hamed Aghajani Derazkola ◽  
Majid Elyasi
Keyword(s):  
Friction Stir Welding ◽  
Methyl Methacrylate ◽  
Material Flow ◽  
Welded Joint ◽  
Welding Process ◽  
Frictional Heat ◽  
Plunge Depth ◽  
Poly Methyl Methacrylate ◽  
Friction Stir ◽  
Thermomechanical Simulation

The effects of tilt angle (TTA), plunge depth (TPD) and offset (TO) of tool in friction stir welding of poly(methyl methacrylate) T-joint were investigated. To understand better the effects of process parameter, thermomechanical simulation of joint was assessed. The results seem to show that at higher TPD and TTA, frictional heat increases. Woven tissue structure joint line forms after friction stir welding of poly(methyl methacrylate) sheets. The distance of woven layers was affected by TPD and TTA, while TO do not significantly affect heat generation of joint. The best material flow and adequate heat are generated at 0 mm TA, 2° TTA and 0.2 mm TPD, respectively. The highest flexural and tensile strength of friction stir welded joint were approximately 93% and 90% of as-received poly(methyl methacrylate), respectively. Crack forking was detected on the fractured surface of flexural samples and crack path was detected in the vicinity of shrinkage holes at fracture surface of tensile samples. These holes and degradation of poly(methyl methacrylate) during friction stir welding process decrease strength and hardness of the joint.

scholarly journals Numerical Simulation of Material Flow and Analysis of Welding Characteristics in Friction Stir Welding Process

Metals ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 621 ◽  
Author(s):  
Haitao Luo ◽  
Tingke Wu ◽  
Peng Wang ◽  
Fengqun Zhao ◽  
Haonan Wang ◽  
...  
Keyword(s):  
Finite Element ◽  
Friction Stir Welding ◽  
Finite Element Model ◽  
Material Flow ◽  
Welding Process ◽  
Element Model ◽  
Welding Seam ◽  
Friction Stir ◽  
Tool Pin ◽  
The Finite Element Model

Friction stir welding (FSW) material flow has an important influence on weld formation. The finite element model of the FSW process was established. The axial force and the spindle torque of the welding process were collected through experiments. The feasibility of the finite element model was verified by a data comparison. The temperature field of the welding process was analyzed hierarchically. It was found that the temperature on the advancing side is about 20 °C higher than that on the retreating side near the welding seam, but that the temperature difference between the two sides of the middle and lower layers was decreased. The particle tracking technique was used to study the material flow law in different areas of the weld seam. The results showed that part of the material inside the tool pin was squeezed to the bottom of the workpiece. The material on the upper surface tends to move downward under the influence of the shoulder extrusion, while the material on the lower part moves spirally upward under the influence of the tool pin. The material flow amount of the advancing side is higher than that of the retreating side. The law of material flow reveals the possible causes of the welding defects. It was found that the abnormal flow of materials at a low rotation speed and high welding speed is prone to holes and crack defects. The forming reasons and material flow differences in different regions are studied through the microstructure of the joint cross section. The feasibility of a finite element modeling and simulation analysis is further verified.

3-D Modeling & Numerical Simulation of Friction Stir Welding Process

2012 ◽  
Vol 488-489 ◽  
pp. 1189-1193 ◽  
Author(s):  
Barnik Saha Roy ◽  
Subhash Chandra Saha ◽  
John Deb Barma
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Mechanical Model ◽  
Equivalent Plastic Strain ◽  
Welding Process ◽  
Traverse Speed ◽  
Nonlinear Finite Element ◽  
Comsol Multiphysics ◽  
Friction Stir ◽  
Aa6061 Aluminium Alloy

A 3D thermal pseudo mechanical model formulated in an Eulerian frame considering a quassisteady approach to Friction Stir welding modeling of AA6061 Aluminium alloy is proposed and implemented using nonlinear finite element code in Comsol Multiphysics v 4.1. The effect of different operating parameters on the temperature distribution was analyzed. The material flow is found to be enhanced with the increase in traverse speed and angular velocity of the pin with a pronounced swirl on the advancing side. The distribution of equivalent plastic strain and dynamic viscosity was found to correlate with the distribution of the microstructure zones in the weld.

Taguchi Analysis of the Effect of Process Parameters in Friction Stir Welding

2010 ◽  
Vol 636-637 ◽  
pp. 1150-1156 ◽  
Author(s):  
Rui Louro ◽  
Carlos Leitão ◽  
Helena Gouveia ◽  
Altino Loureiro ◽  
Dulce Maria Rodrigues
Keyword(s):  
Friction Stir Welding ◽  
Taguchi Method ◽  
Welding Process ◽  
Experimental Tests ◽  
Experimental Methods ◽  
Butt Joint ◽  
Welding Parameters ◽  
Published Data ◽  
Friction Stir ◽  
Friction Stir Welding Process

The task of obtaining suitable welding parameters for the friction stir welding process is often a difficult one, due to the lack of published data and the fact that the exact mechanism by which the process operates has not yet been fully determined. Therefore, suitable welding parameters often need to be obtained by using extensive, time consuming and expensive experimental methods. The work detailed in this paper pertains to the use of the Taguchi method as a mean to reduce the disadvantages of these experimental methods, more specifically, their cost. The Taguchi method accomplishes this task by substantially reducing the number of welding trials that are needed to obtain suitable welding parameters. This reduction leads to the parameters being obtained more rapidly and at a substantially smaller cost. In this paper a procedure for applying the Taguchi method to the friction stir welding process is presented as well as its application to the welding of a specific component. The method was applied to the welding of 4mm thick AA5083-H111 plates in a butt joint configuration, which constitutes one of the most common industrial welding scenarios. The purpose of the experimental tests was to maximize the welding speed whilst ensuring an acceptable welding quality. The quality of the welds was determined through visual inspection and tensile and bending tests. The application of the Taguchi method allowed, with a relatively small number of experimental welds, to provide some insight into the manner by which the parameters should be altered in order to optimize the process.

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