Prediction of Heat Generation during Friction Stir Welding of an Aluminium Alloy

2016 ◽  
Vol 852 ◽  
pp. 260-266
Author(s):  
M. Selvaraj ◽  
G. Selvakumar
Keyword(s):  
Heat Flux ◽  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Heat Generation ◽  
Rotational Speed ◽  
Material Flow ◽  
Welding Process ◽  
Friction Stir ◽  
Temperature Heat ◽  
6061 Aluminium Alloy

The heat generation during friction stir welding process influences the material flow, microstructure, and mechanical properties of the friction stir welded plates. This paper proposes a model for predicting heat generation and heat flux during the friction stir welding of AA 6061 aluminium alloy. The heat generation as a function of temperature, heat flux at the shoulder as a function of temperature, radius of shoulder and rotational speed and heat flux at the pin as function of temperature, radius of shoulder and rotational speed have been discussed. It shows that heat generation is inversely proportional to temperature, the heat flux at the shoulder and pin are directly proportional to radius of shoulder and rotational speed and inversely proportional to temperature.

scholarly journals Optimization of Process Parameters for Friction Stir Welding of Dissimilar Aluminium Alloy AA6061 to AA5183 using TOPSIS Technique

2019 ◽  
Vol 8 (9S3) ◽  
pp. 1315-1319
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Rotational Speed ◽  
Transverse Velocity ◽  
Welding Process ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Optimum Process ◽  
Tool Rotational Speed ◽  
Friction Stir

Friction stir welding has proven to be the most promising solid state joining process. It can be used to get high weldability in joining of high strength aerospace aluminium alloys and other metallic alloys which used to be low with traditional fusion welding process. This paper emphasises on finding the optimum process parameter for friction stir welding of dissimilar aluminium alloy AA6061 to AA5183 using multi criteria decision making method (MCDM). Friction stir welding was done at different tool rotational speed and transverse velocity and mechanical properties such as tensile strength, percentage elongation and hardness were studied for each weld specimen. Finally optimization was done using TOPSIS (Techniqueof Ordered Preference by Similarity to Ideal Solution). The result revealed that the tool rotational speed of 1200 rpm and welding speed of 80mm/min are the optimum welding parameters.

scholarly journals Optimization of Process Parameters for Friction Stir Welding of Dissimilar Aluminium Alloy AA6061 to AA5183 using TOPSIS Technique

2019 ◽  
Vol 8 (2S3) ◽  
pp. 1625-1629
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Rotational Speed ◽  
Transverse Velocity ◽  
Welding Process ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Optimum Process ◽  
Tool Rotational Speed ◽  
Friction Stir

Friction stir welding has proven to be the most promising solid state joining process. It can be used to get high weldability in joining of high strength aerospace aluminium alloys and other metallic alloys which used to be low with traditional fusion welding process. This paper emphasises on finding the optimum process parameter for friction stir welding of dissimilar aluminium alloy AA6061 to AA5183 using multi criteria decision making method (MCDM). Friction stir welding was done at different tool rotational speed and transverse velocity and mechanical properties such as tensile strength, percentage elongation and hardness were studied for each weld specimen. Finally optimization was done using TOPSIS (Techniqueof Ordered Preference by Similarity to Ideal Solution). The result revealed that the tool rotational speed of 1200 rpm and welding speed of 80mm/min are the optimum welding parameters

An analytical and experimental investigation considering the effect of material flow velocity on tensile strength of a steel alloy joint produced by friction stir welding process

2020 ◽  
pp. 095440622093631
Author(s):  
Behzad Hadi ◽  
ME Aalami-Aleagha ◽  
Saeed Feli
Keyword(s):  
Friction Stir Welding ◽  
Flow Velocity ◽  
Analytical Method ◽  
Rotational Speed ◽  
Material Flow ◽  
Welding Process ◽  
Linear Speed ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Tool Pin

In this paper, the effects of linear speed, rotational speed, and tool radius of the pin and shoulder are investigated on the material flow velocity in friction stir welds. To obtain the maximum material flow velocity by an analytical method, a suggested relation is introduced for the rotational speed and tool optimum radius. The derived relation is based on the assumption of a velocity field in the stirring region. Besides, the effect of the linear speed on material flow velocity is investigated based on continuity and momentum equations. Finally, by using the experimental method and checking the mechanical properties of the welded parts obtained with different rotational speed, linear speed, and tool dimensions, the proposed analytical model is validated. The results indicate that in the friction stir welding process, the significant component effect on the stirring process is generated through the tool pin radius size. Besides, increasing the material flow velocity in the boundary layer increases the yield and ultimate strength of welds. To achieve the high-quality welds, rotational speed and other tool dimensions must be selected considering the equation extracted from the analytical method. Also, to make the maximum life for the pin and its components in friction stir welding of high melting point metals such as steel alloys, the operation is adjusted at a lower linear speed to prevent the destruction of the tool and improve the quality of the joint.

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 Analysis of the influence of position of welding materials on the FSW seams properties for three dissimilar aluminium alloy

2018 ◽  
Vol 178 ◽  
pp. 03003 ◽  
Author(s):  
Ana Bosneag ◽  
Marius Adrian Constantin ◽  
Eduard Niţu ◽  
Monica Iordache
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Arc Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Workpiece Material ◽  
Friction Stir ◽  
Welding Joints ◽  
Welding Materials

Friction Stir Welding, abbreviated FSW is a new and innovative welding process. This welding process is increasingly required, more than traditional arc welding, in industrial environment such us: aeronautics, shipbuilding, aerospace, automotive, railways, general fabrication, nuclear, military, robotics and computers. FSW, more than traditional arc welding, have a lot of advantages, such us the following: it uses a non-consumable tool, realise the welding process without melting the workpiece material, can be realised in all positions (no weld pool), results of good mechanical properties, can use dissimilar materials and have a low environmental impact. This paper presents the results of experimental investigation of friction stir welding joints to three dissimilar aluminium alloy AA2024, AA6061 and AA7075. For experimenting the value of the input process parameters, the rotation speed and advancing speed were kept the same and the position of plates was variable. The exit date recorded in the time of process and after this, will be compared between them and the influence of position of plate will be identified on the welding seams properties and the best position of plates for this process parameters and materials.

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.

scholarly journals A Modified Analytical Heat Source Model for Numerical Simulation of Temperature Field in Friction Stir Welding

2020 ◽  
Vol 2020 ◽  
pp. 1-16
Author(s):  
Xiangqian Liu ◽  
Yan Yu ◽  
Shengli Yang ◽  
Huijie Liu
Keyword(s):  
Heat Flux ◽  
Friction Stir Welding ◽  
Analytical Model ◽  
Heat Generation ◽  
Tilt Angle ◽  
Temperature Fields ◽  
Analytical Models ◽  
Maximum Temperature ◽  
Thermal Cycles ◽  
Friction Stir

In the conventional analytical model used for heat generation in friction stir welding (FSW), the heat generated at the pin/workpiece interface is assumed to distribute uniformly in the pin volume, and the heat flux is applied as volume heat. Besides, the tilt angle of the tool is assumed to be zero for simplicity. These assumptions bring about simulating deviation to some extent. To better understand the physical nature of heat generation, a modified analytical model, in which the nonuniform volumetric heat flux and the tilt angle of the tool were considered, was developed. Two analytical models are then implemented in the FEM software to analyze the temperature fields in the plunge and traverse stage during FSW of AA6005A-T6 aluminum hollow extrusions. The temperature distributions including the maximum temperature and heating rate between the two models are different. The thermal cycles in different zones further revealed that the peak temperature and temperature gradient are very different in the high-temperature region. Comparison shows that the modified analytical model is accurate enough for predicting the thermal cycles and peak temperatures, and the corresponding simulating precision is higher than that of the conventional analytical model.

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