Finite Element Analysis of Materials Flow Behavior in Friction Stir Welding of 7075 Aluminum Alloy Plate

A 3D elastic-plastic and coupled thermo-mechanical FE model for friction stir welding(FSW) of 7075 aluminum alloy plate was developed based on the dynamic explicit code ABAQUS/explicit, then the FSW process of 7075 aluminum alloy plate was simulated and the materials flow behavior was analyzed. The results show that in the horizontal direction of the plate, two patterns of materials migration are produced: (1) the material rotates with the tool and finally deposits the tentative cavity behind the pin; (2) the material transfers in the mode of laminar flow. Furthermore, the streamlines of material in advanced side (AS) are bent along the reverse welding direction. After bypassing the pin, the material of retreating side (RS) moves backward it, and extends to AS.

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A 3D Coupled Thermo-Mechanical FE Model for Friction Stir Welding of 7075 Aluminum Alloy Plate

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.314-316.346 ◽

2011 ◽

Vol 314-316 ◽

pp. 346-350 ◽

Cited By ~ 1

Author(s):

Zheng Hua Guo ◽

Gang Yao Zhao ◽

Li Ming Ke ◽

Li Xing ◽

Shun Feng Zhu

Keyword(s):

Plastic Deformation ◽

Aluminum Alloy ◽

Friction Stir Welding ◽

Bottom Surface ◽

Fe Model ◽

7075 Aluminum Alloy ◽

Alloy Plate ◽

Friction Stir ◽

Plastic Deformation Behavior ◽

Aluminum Alloy Plate

Friction stir welding(FSW), a new solid-state joining process, is wildly used in the fields of aviation, aerospace and other high technology industries for many advantages over traditional fusion welding. Computer modeling is an important tool for the prediction and optimization of the FSW process. According to the characteristics of FSW of 7075 aluminum alloy plate, a 3D coupled thermo-mechanical FE model of this process was built under the ABAQUS/explicit environment based on the solution of several key techniques, such as heat boundary condition treating, material properties definition, ALE adaptive meshing technology, etc., and validated experimentally. Then, simulation and analysis of the complex plastic deformation behavior of the process were carried out. The results show that in the stable stage of the welding, the zone of equivalent plastic deformation decreases from the top surface of weld to the bottom surface; the plastic deformation of metal ahead of the welding tool is larger than that behind the welding tool; moreover the zone of equivalent plastic deformation is concentrated behind the tool.

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Research on Joint Strength of Aluminum Alloy Welded by FSW

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.590.249 ◽

2014 ◽

Vol 590 ◽

pp. 249-253 ◽

Cited By ~ 1

Author(s):

Chuan Hong Luo ◽

Ting Chen ◽

Wei Ping Peng

Keyword(s):

Aluminum Alloy ◽

Friction Stir Welding ◽

Joint Strength ◽

Nugget Zone ◽

Alloy Plate ◽

Friction Stir ◽

Transverse Tensile ◽

Plastic Damage ◽

Aluminum Alloy Plate ◽

Transverse Tensile Strength

The joint of 2219-T6 aluminum alloy plate was obtained by friction stir welding, and the microstructures and mechanical properties of the joint were investigated. The causes of the weakened joint strength in friction stir welding were analyzed and summarized correspondingly. The tensile properties show that the transverse tensile strength of the joint can reach about 70% of the base metal and the elongation can reach about 7%. The main reason of the weakened strength is due to the plastic damage of metal, followed by the defects generated in the nugget zone and the growth of θ phase in the heat affected zone.

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Effect of Residual Aluminum Thickness on Microstructure and Strength of Friction Stir Spot Welded Aluminum Alloy/Copper Lap Joint

Materials Science Forum ◽

10.4028/www.scientific.net/msf.1042.3 ◽

2021 ◽

Vol 1042 ◽

pp. 3-8

Author(s):

Mitsuhiro Watanabe ◽

Shinpei Sasako

Keyword(s):

Aluminum Alloy ◽

Pure Copper ◽

Optical Microscope ◽

Copper Plate ◽

Laminate Structure ◽

Alloy Plate ◽

Friction Stir ◽

Residual Aluminum ◽

Welding Interface ◽

Aluminum Alloy Plate

Dissimilar metal lap joining of A5052 aluminum alloy plate and C1100 pure copper plate was performed by using friction stir spot welding. The rotating welding tool, which was composed of a probe part and a shoulder part, was plunged from the aluminum alloy plate which was overlapped on the copper plate, and residual aluminum alloy thickness under the probe part of the welding tool after plunging of the welding tool was controlled in the range from 0 mm to 0.4 mm. The strength of the welding interface was evaluated by using tensile-shear test. Microstructure of the welding interface was examined by using an optical microscope and a field emission scanning electron microscope. The welding was achieved at the residual aluminum alloy thickness under the probe part of the welding tool below 0.3 mm. The welded area was formed at aluminum alloy/copper interface located under the probe part of the welding tool, and its width increased with decreasing the residual aluminum alloy thickness. A characteristic laminate structure was produced in the copper matrix near the welding interface. In the joint fabricated at the residual aluminum alloy thickness below 0.1 mm, hook of Cu was formed at edge of the welded area. The fracture did not occur at the welding interface. A remarkable improvement in strength was observed in the joint fabricated at the residual aluminum alloy thickness below 0.1 mm. The formation of laminate structure and hook is considered to result in joint strength improvement.

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Study on spray cooling characteristics of 7075 aluminum alloy plate

Heat Transfer Research ◽

10.1615/heattransres.2022039632 ◽

2022 ◽

Author(s):

yongbang miao ◽

Ruifeng Dou ◽

Zhi Wen ◽

Xunliang Liu ◽

Cheng Zhu

Keyword(s):

Aluminum Alloy ◽

Spray Cooling ◽

7075 Aluminum Alloy ◽

Alloy Plate ◽

Aluminum Alloy Plate

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Surface Smoothing of A5083 Aluminum Alloy Plate by Friction Stir Forming

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.803.50 ◽

2019 ◽

Vol 803 ◽

pp. 50-54

Author(s):

Takahiro Ohashi ◽

Kento Okuda ◽

Hamed Mofidi Tabatabaei ◽

Tadashi Nishihara

Keyword(s):

Aluminum Alloy ◽

Feed Rate ◽

Metal Plate ◽

Spindle Speed ◽

Back Surface ◽

Alloy Plate ◽

Friction Stir ◽

Shoulder Diameter ◽

Aluminum Alloy Plate ◽

Aluminum Plates

This paper provides a framework for the transcription of the surface of a mirror-finished die onto a metal plate by friction stir forming (FSF). In FSF, a material is put on a die, then friction stirring was conducted on its back surface for the transcription of the profile of the die onto the material. In this paper, a mirror-polished die of JIS SUS304 stainless steel with surface roughness Sz 0.014 mm and a probe-less friction-stirring tool in 18 mm shoulder diameter were employed for the experiment. A5083P-O aluminum plates, 3 mm thick, were utilized as base metals for the transcription. The authors varied tool spindle speed and tool feed rate to evaluate the forming results. Consequently, a mirror-finished surface under the friction-stirring tool was successfully transferred from the die to the aluminum alloy plate. The roughness of the base metal before processing was Sz 0.022 mm and that of the processed metal was Sz 0.012–0.016 mm. Higher spindle speed and faster feed rate resulted in a smoother surface; it is thought that high spindle speed and faster feed rate should be effective for higher contact pressure between a die and a material.

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Study on the Precipitation Behavior of Precipitates of 7075 Aluminum Alloy Friction Stir Welding Joint

Materials Science Forum ◽

10.4028/www.scientific.net/msf.1003.37 ◽

2020 ◽

Vol 1003 ◽

pp. 37-46

Author(s):

Hao Zhu ◽

Shao Kang Dong ◽

Ze Ming Ma ◽

Jun Wang

Keyword(s):

Aluminum Alloy ◽

Friction Stir Welding ◽

Strain Hardening ◽

Strengthening Effect ◽

7075 Aluminum Alloy ◽

Friction Stir ◽

Microhardness Distribution ◽

Fine Grain ◽

Fine Grain Strengthening ◽

Precipitated Phases

In this work, the microhardness of 7075 aluminum alloy friction stir welding (FSW) joint was measured by a micro vickers hardness tester, the microstructure of the joints was characterised by microscope, the precipitated phases among the welding nugget zone (WNZ), thermal mechanical affected zone (TMAZ), heat affected zone (HAZ) were affirmed by X-ray diffractometer (XRD) and the lattice fringe of transmission electron microscopy (TEM) high resolution image. Based on this, the precipition behavior of precipitated phases was studied. The results show that the microhardness distribution of the 7075 aluminium alloy FSW joints is heterogeneous in comparison with the base metal (BM). The precipitates in the joint mainly include MgZn rod shape and AlCuMg in elliptical shape. In the WNZ, the main precipitate is AlCuMg, and the fine grain strengthening effect is better, so the microhardness in this zone is relatively high. In the TMAZ, the quantity of AlCuMg decreased while the MgZn2 increased relatively in comparison with the WNZ. At the same time, the effect of the fine grain strengthening was weakened, though the strain hardening increased. Therefore, the microhardness in the TMAZ still decreased. In the HAZ, the quantity of MgZn2 increased furtherly, and there is no strain hardening and fine grain strengthening, so the microhardness of the HAZ was the lowest among the FSW joints. Besides, through comparative tests, the optimal process parameters of friction stir welding of 7075 aluminum alloy were obtained.

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Influence of Heat Treatment on Properties of 2219AA-T6 FSW Joints

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.590.187 ◽

2014 ◽

Vol 590 ◽

pp. 187-191 ◽

Cited By ~ 1

Author(s):

Chuan Hong Luo ◽

Wei Ping Peng ◽

Ting Chen ◽

Fei Bo Dong

Keyword(s):

Mechanical Properties ◽

Heat Treatment ◽

Friction Stir Welding ◽

Joint Strength ◽

Alloy Plate ◽

Friction Stir ◽

Transverse Tensile ◽

Aluminum Alloy Plate ◽

Transverse Tensile Strength ◽

Short Time

The joint of 2219-T6 aluminum alloy plate was obtained by friction stir welding, and the microstructures and mechanical properties of the joint were investigated. The causes of the weakened joint strength in friction stir welding were analyzed and summarized correspondingly. The tensile properties show that the transverse tensile strength of the joint can reach about 70% of the base metal. Through the heat treatment of recrystallization with high temperature and at short time, the joint can restore the ductility and eliminate the softening, which will improve the performance in mechanical intensity of the joint.

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