scholarly journals Effects of FSW Tool Plunge Depth on Properties of an Al-Mg-Si Alloy T-Joint: Thermomechanical Modeling and Experimental Evaluation

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4754
Author(s):  
Shabbir Memon ◽  
Dariusz Fydrych ◽  
Aintzane Conde Fernandez ◽  
Hamed Aghajani Derazkola ◽  
Hesamoddin Aghajani Derazkola
Keyword(s):  
Material Flow ◽  
Defect Formation ◽  
Stir Zone ◽  
Frictional Heat ◽  
Plunge Depth ◽  
Friction Stir ◽  
Stiffened Structures ◽  
Simulation Results ◽  
Cfd Method ◽  
Welding Processes

One of the main challenging issues in friction stir welding (FSW) of stiffened structures is maximizing skin and flange mixing. Among the various parameters in FSW that can affect the quality of mixing between skin and flange is tool plunge depth (TPD). In this research, the effects of TPD during FSW of an Al-Mg-Si alloy T-joint are investigated. The computational fluid dynamics (CFD) method can help understand TPD effects on FSW of the T-joint structure. For this reason, the CFD method is employed in the simulation of heat generation, heat distribution, material flow, and defect formation during welding processes at various TPD. CFD is a powerful method that can simulate phenomena during the mixing of flange and skin that are hard to assess experimentally. For the evaluation of FSW joints, macrostructure visualization is carried out. Simulation results showed that at higher TPD, more frictional heat is generated and causes the formation of a bigger stir zone. The temperature distribution is antisymmetric to the welding line, and the concentration of heat on the advancing side (AS) is more than the retreating side (RS). Simulation results from viscosity changes and material velocity study on the stir zone indicated that the possibility of the formation of a tunnel defect on the skin–flange interface at the RS is very high. Material flow and defect formation are very sensitive to TPD. Low TPD creates internal defects with incomplete mixing of skin and flange, and high TPD forms surface flash. Higher TPD increases frictional heat and axial force that diminish the mixing of skin and flange in this joint. The optimum TPD was selected due to the best materials flow and final mechanical properties of joints.

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.

Prediction of Surface Profile in Friction Stir Welding Using Coupled Eulerian and Lagrangian Method

2020 ◽  
Author(s):  
Debtanay Das ◽  
Swarup Bag ◽  
Sukhomay Pal ◽  
M. Ruhul Amin
Keyword(s):  
Friction Stir Welding ◽  
Surface Morphology ◽  
Process Parameters ◽  
Chip Formation ◽  
Material Flow ◽  
Defect Formation ◽  
Current Model ◽  
Surface Profile ◽  
Green Technology ◽  
Friction Stir

Abstract Friction stir welding (FSW) is widely accepted by industry because of multiple advantages such as low-temperature process, green technology, and capable of producing good quality weld joints. Extensive research has been conducted to understand the physical process and material flow during FSW. The published works mainly discussed the effects of various process parameters on temperature distribution and microstructure formation. There are few works on the prediction of defect formation from a physics-based model. However, these models ignore chip formation or surface morphology and material loss during the FSW process. In the present work, a fully coupled 3D thermo-mechanical model is developed to predict the chip formation and surface morphology during welding. The effects of various process parameters on surface morphology are also studied using the current model. Coupled Eulerian-Lagrangian (CEL) technique is used to model the FSW process using a commercial software ABAQUS. The model is validated by comparing the results in published literature. The current model is capable of predicting the material flow out of the workpiece and thus enables the visualization of the chip formation. The developed model can extensively be used to predict the surface quality of the friction stir welded joints.

Material flow and void defect formation in friction stir welding of aluminium alloys

2018 ◽  
Vol 23 (8) ◽  
pp. 677-686 ◽  
Author(s):  
X. H. Zeng ◽  
P. Xue ◽  
D. Wang ◽  
D. R. Ni ◽  
B. L. Xiao ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Material Flow ◽  
Defect Formation ◽  
Void Defect ◽  
Friction Stir

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.

Friction Based Solid State Welding Processes

2012 ◽  
Vol 504-506 ◽  
pp. 3-14 ◽  
Author(s):  
Livan Fratini ◽  
Gianluca Buffa ◽  
Dario la Spisa
Keyword(s):  
Solid State ◽  
Material Flow ◽  
Research Issues ◽  
Friction Stir ◽  
Linear Friction ◽  
Process Mechanics ◽  
Frictional Forces ◽  
Industrial Use ◽  
Mechanical Performances ◽  
Welding Processes

In the last decade the industrial use of solid state welding processes based on frictional forces work decaying into heat is continuously increasing due to their strong advantages with respect to traditional fusion techniques. Several advances have been proposed by the scientific community regarding process mechanics, material flow and also the computer aided engineering of the operation with the aim to maximize the mechanical performances of the welded joints. In the paper Friction Stir Welding (FSW) and Linear Friction Welding (LFW) operations are considered and a review of the most relevant research issues and results is provided.

Influence of Nano Reinforcement Volume Percentage on Fabrication of Surface Nanocomposite by FSP

2016 ◽  
Vol 879 ◽  
pp. 1369-1374
Author(s):  
P. Naresh ◽  
Adepu Kumar ◽  
M. Krishna Kishore
Keyword(s):  
Material Flow ◽  
Volume Fraction ◽  
Traverse Speed ◽  
Stir Zone ◽  
Tool Rotational Speed ◽  
Volume Percentage ◽  
Phase Volume Fraction ◽  
Friction Stir ◽  
Surface Composite

This work deals with the effect of volume percentage of nanoreinforcement to fabricate nanosurface composite by Friction Stir Processing (FSP) and also studied the role of tool rotational speed and traverse speed to get the defect free condition to fabricate successful surface composite. The material flow pattern, dispersion of the reinforcement particles in the stir zone was examined. From the phase/volume fraction analysis, it was observed that the nanoAl2O3 particles were well dispersed in the stir zone. The results indicate that the better microstructural, mechanical properties were obtained at 1150rpm /15mm/min condition. A significant improvement in microhardness was exhibited by surface nanocomposite as compared to the as - received aluminum.

scholarly journals Estimation of Material Flow in Stir Zone during Friction Stir Welding by Distribution Measurement of Si Particles

2006 ◽  
Vol 47 (1) ◽  
pp. 224-232 ◽  
Author(s):  
Hidetoshi Fujii ◽  
Young Gon Kim ◽  
Takuya Tsumura ◽  
Toru Komazaki ◽  
Kazuhiro Nakata
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Stir Zone ◽  
Distribution Measurement ◽  
Friction Stir

scholarly journals Friction Stir Welding and Friction Spot Stir Welding Processes of Polymers—State of the Art

Materials ◽  
2020 ◽  
Vol 13 (10) ◽  
pp. 2291 ◽  
Author(s):  
Francesco Lambiase ◽  
Hamed Aghajani Derazkola ◽  
Abdolreza Simchi
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
State Of The Art ◽  
Online Measurement ◽  
Future Perspectives ◽  
Influence Of Process Parameters ◽  
New Developments ◽  
Friction Stir ◽  
Academic Researchers ◽  
Welding Processes

In the last decade, the friction stir welding of polymers has been increasingly investigated by the means of more and more sophisticated approaches. Since the early studies, which were aimed at proving the feasibility of the process for polymers and identifying suitable processing windows, great improvements have been achieved. This owes to the increasing care of academic researchers and industrial demands. These improvements have their roots in the promising results from pioneer studies; however, they are also the fruits of the adoption of more comprehensive approaches and the multidisciplinary analyses of results. The introduction of instrumented machines has enabled the online measurement of processing loads and temperature, and critical understanding of the principal aspects affecting the material flow and welds quality. Such improvements are also clearly demonstrated by the increase of the strength of recent joints (up to 99% of joining efficiency) as compared to those reached in early researches (almost 47%). This article provides a comprehensive review of the recent progresses on the process fundamentals, quality assessment and the influence of process parameters on the mechanical behavior. In addition, emphasis is given to new developments and future perspectives.

Effect of Friction Stir Welding pin Shape on Mechanical Properties of AA6061 Alloy Weldment

2013 ◽  
Vol 465-466 ◽  
pp. 1309-1313
Author(s):  
Mohd Hasbullah Idris ◽  
Mohd Shamsul Husin
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Material Flow ◽  
Weld Line ◽  
Butt Joint ◽  
Hardness Distribution ◽  
Plunge Depth ◽  
Friction Stir ◽  
Joint Properties

The present study is aimed to determine the effect of friction stir welding pin; square and diamond shape on mechanical properties of butt joint AA6061 weldment. Welding was carried out at different plunge depths of 0.0, 0.2, 0.3 and 0.4 mm together with rotation and transverse speeds of 500 rpm and 40 mm/min, respectively. Material flow, tensile strength and hardness of the weldment were evaluated. The results indicated that joint properties were significantly affected by tool design. It was found that material flow was higher for diamond pin tool compared to that of square pin resulting in considerable increased in tensile strength of the joint. In addition, the highest tensile strength was obtained on the samples welded with square shape pin at 0.4 mm plunge depth whilst the lowest was by diamond shape at the plunge depth of 0.0 mm. Regardless of pin shape and plunge depth; asymmetrical hardness distribution was observed for all weldments. The highest hardness was found to be close to the weld line produced by the diamond shaped pin at 0.0 mm plunge depth.

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