scholarly journals Temperature based validation of the analytical model for the estimation of the amount of heat generated during friction stir welding

2012 ◽  
Vol 16 (suppl. 2) ◽  
pp. 337-350 ◽  
Author(s):  
Dragan Milcic ◽  
Miroslav Mijajlovic ◽  
Nenad Pavlovic ◽  
Mica Vukic ◽  
Dragan Mancic
Keyword(s):  
Friction Stir Welding ◽  
Analytical Model ◽  
Material Flow ◽  
Mechanical Energy ◽  
Relative Difference ◽  
Parent Material ◽  
Contact Conditions ◽  
Friction Stir ◽  
Influence Of Temperature On ◽  
Welding Technique

Friction stir welding is a solid-state welding technique that utilizes thermomechanical influence of the rotating welding tool on parent material resulting in a monolith joint - weld. On the contact of welding tool and parent material, significant stirring and deformation of parent material appears, and during this process, mechanical energy is partially transformed into heat. Generated heat affects the temperature of the welding tool and parent material, thus the proposed analytical model for the estimation of the amount of generated heat can be verified by temperature: analytically determined heat is used for numerical estimation of the temperature of parent material and this temperature is compared to the experimentally determined temperature. Numerical solution is estimated using the finite difference method - explicit scheme with adaptive grid, considering influence of temperature on material's conductivity, contact conditions between welding tool and parent material, material flow around welding tool, etc. The analytical model shows that 60-100% of mechanical power given to the welding tool is transformed into heat, while the comparison of results shows the maximal relative difference between the analytical and experimental temperature of about 10%.

scholarly journals Numerical simulation of friction stir welding

2014 ◽  
Vol 18 (3) ◽  
pp. 967-978 ◽  
Author(s):  
Miroslav Mijajlovic ◽  
Dragan Milcic ◽  
Miodrag Milcic
Keyword(s):  
Numerical Simulation ◽  
Friction Stir Welding ◽  
Mechanical Energy ◽  
Parent Material ◽  
Contact Conditions ◽  
Friction Stir ◽  
Influence Of Temperature On ◽  
Mechanical Influence ◽  
Welding Technique ◽  
Good Agreement

Friction stir welding is a solid-state welding technique that utilizes thermo-mechanical influence of the rotating welding tool on parent material resulting with monolith joint-weld. On the contact of welding tool and parent material, significant stirring and deformation of parent material appears, and during this process mechanical energy is partially transformed into heat. The paper describes the software for the numerical simulation of friction stir welding developed at Mechanical Engineering Faculty, University of Nis. Numerical solution for estimation of welding plates temperature is estimated using finite difference method-explicit scheme with adaptive grid, considering influence of temperature on material's conductivity, contact conditions between welding tool and parent material, material flow around welding tool etc. The calculated results are in good agreement with the experimental results.

Influence of Tool Geometry and Contact Condition on Friction Stir Welding of Al-Cu Laminated Composites

2013 ◽  
Vol 856 ◽  
pp. 16-21
Author(s):  
R. Beygi ◽  
Mohsen Kazeminezhad ◽  
A.H. Kokabi ◽  
S. Mohammad Javad Alvani ◽  
D. Verdera ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Laminated Composites ◽  
Flow Behavior ◽  
Tool Geometry ◽  
Contact Conditions ◽  
Friction Stir ◽  
Tool Geometries ◽  
Welding Procedure ◽  
Sem Analyses

In this study friction stir welding of Al-Cu laminated composites were carried out by two different tool geometries. Welding procedure was carried out from both sides of Al and Cu. Analyzing cross section of welds showed that different contact conditions between shoulder and material, offers different material flow behavior which is dependent on the tool geometry. SEM analyses showed that mixing of materials in nugget region is more pronounced in the advancing side. Also XRD results indicated that welding from Cu side, leads to intermetallic formation in mixed regions.

scholarly journals A Modified Friction Stir Welding Process Based on Vortex Material Flow

2020 ◽  
Vol 33 (1) ◽  
Author(s):  
Xiaochao Liu ◽  
Yunqian Zhen ◽  
Zhikang Shen ◽  
Haiyan Chen ◽  
Wenya Li ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Tool Wear ◽  
Material Flow ◽  
Pure Aluminum ◽  
Welding Process ◽  
Friction Stir ◽  
New Process ◽  
Identical Material ◽  
Micro Structures ◽  
Welding Technique

AbstractFriction stir welding is a promising solid-state welding technique. However, the issue of tool wear and break restricts its wider industrial application. To avoid the tool wear and break occurring in conventional friction stir welding (FSW), a new modification of the FSW process using a tool made by the identical material as the workpiece has been developed and conducted on pure aluminum. We named this process as Vortex-FSW (VFSW) because it depends on a vortex material flow to realize the welding and joining. The weld macro- and micro-structures are like that in conventional FSW. However, the tool exit-hole in conventional FSW is replaced by a lug boss. The mechanical properties are also equivalent to that in conventional FSW. The principle of this new process is introduced in this paper.

scholarly journals A novel double-side welding approach for friction stir welding of polypropylene plate

2021 ◽  
Author(s):  
Rahul Kanti Nath ◽  
Vinayak Jha ◽  
Pabitra Maji ◽  
John Deb Barma
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Polymer Materials ◽  
High Demand ◽  
Cross Sectional ◽  
Friction Stir ◽  
Novel Approach ◽  
Single Side ◽  
Cost Efficient ◽  
Welding Technique

AbstractIn almost every industry, polymer materials are in high demand in recent years due to their lightweight and easy formability. However, eco-friendly, cost-efficient and defect-free joining of polymers is a major concern. In this article, a novel approach is taken for friction stir welding of polypropylene by implementing a double-side welding technique. The effect of tool rotational speed on construction and properties of the welded joints are studied. The torque and forces exerted on the tool during double-side welding are compared with single-side welding. Cross-sectional morphology examination using optical and scanning electron microscope reveals defect-free sound welding by double-side weld with uniform material flow. The molecular bonds of the welded specimens are examined by FTIR analysis. The double-side welding technique yields superior joints in terms of tensile strength and flexural strength than the joints obtained by single-side welding.

Effect of Porosity Content on the Weldability of Powder Metal Parts Produced by Friction Stir Welding

2007 ◽  
Vol 534-536 ◽  
pp. 789-792 ◽  
Author(s):  
Adem Kurt ◽  
Ilyas Uygur ◽  
Hakan Ates
Keyword(s):  
Friction Stir Welding ◽  
Powder Metal ◽  
Aluminum Powders ◽  
Friction Stir ◽  
Metal Parts ◽  
Constant Friction ◽  
Sintered Powder ◽  
Hardness Values ◽  
Welding Technique ◽  
Traveling Speed

Friction stir welding technique (FSW) has many advantages in terms of tool design, rotational speed and traveling speed, and can be adjusted in a precise manner. It enables heat input into the system to be controlled. In this study, Aluminum powders were compacted at 350,400 and 450 MPa pressure and sintered at 450 oC temperature for 30 minutes in Ar atmosphere. Sintered powder metal parts were joined to each other by FSW at the speed of 1800 rpm and traveling welding speed 200 mm/min under a constant friction force. The results show that the amount of porosity affects the weldability of powder metallurgy (P/M) parts. Furthermore, the porosity and microstructural evolution of the Aluminum also affected the hardness values of the tested materials.

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.

scholarly journals Friction Stir Welding of AA2024-T3 plate – the influence of different pin types

2015 ◽  
Vol 6 (1) ◽  
pp. 51-55 ◽  
Author(s):  
D. Trimble ◽  
H. Mitrogiannopoulos ◽  
G. E. O'Donnell ◽  
S. McFadden
Keyword(s):  
Friction Stir Welding ◽  
Parent Material ◽  
Micro Hardness ◽  
Workpiece Material ◽  
Friction Stir ◽  
Hardness Tests ◽  
Weld Profile ◽  
Unaffected Parent ◽  
Line Defects ◽  
Tool Pin

Abstract. Some aluminium alloys are difficult to join using traditional fusion (melting and solidification) welding techniques. Friction Stir Welding (FSW) is a solid-state welding technique that can join two plates of material without melting the workpiece material. This proecess uses a rotating tool to create the joint and it can be applied to alumium alloys in particular. Macrostructure, microstructure and micro hardness of friction stir welded AA2024-T3 joints were studied. The influence of tool pin profile on the microstructure and hardness of these joints was examined. Square, triflute and tapered cylinder pins were used and results from each weldment are reported. Vickers micro hardness tests and grain size measurements were taken from the transverse plane of welded samples. Distinct zones in the macrostructure were evident. The zones were identified by transitions in the microstructure and hardness of weld samples. The zones identified across the sample were the the unaffected parent metal, the Heat Affected Zone (HAZ), the Thermo-Mechanicaly Affected Zone (TMAZ), and the Nugget Zone (NZ). Measured hardness values varied through each FSW zone. The hardness in each zone was below that of the parent material. The HAZ had the lowest hardness across the weld profile for each pin type tested. The cylindrical pin consistently produced tunnel and joint-line defects. Pin profiles with flat surface features and/or flutes produced consolidated joints with no defects.

Grain Structure Formation Ahead of Tool during Friction Stir Welding of AZ31 Magnesium Alloy

2010 ◽  
Vol 160 ◽  
pp. 313-318 ◽  
Author(s):  
Uceu Suhuddin ◽  
Sergey Mironov ◽  
H. Takahashi ◽  
Yutaka S. Sato ◽  
Hiroyuki Kokawa ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Structure Formation ◽  
Material Flow ◽  
Boundary Migration ◽  
Deformation Mode ◽  
Grain Structure ◽  
Az31 Magnesium Alloy ◽  
Structure Evolution ◽  
Friction Stir

The “stop-action” technique was employed to study grain structure evolution during friction-stir welding of AZ31 magnesium alloy. The grain structure formation was found to be mainly governed by the combination of the continuous and discontinuous recrystallization but also involved geometric effect of strain and local grain boundary migration. Orientation measurements showed that the deformation mode was very close to the simple shear associated with the rotating pin and material flow arose mainly from basal slip.

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