Thermo-Mechanical Coupled Analysis of Deformation Behavior in Friction Stir Welding Process of Aluminum 7075 Plate with Conical Pin

2011 ◽  
Vol 338 ◽  
pp. 618-621
Author(s):  
Zheng Hua Guo ◽  
Gang Yao Zhao ◽  
Li Ming Ke ◽  
Li Xing ◽  
Hai Li Li
Keyword(s):  
Friction Stir Welding ◽  
Deformation Behavior ◽  
Maximum Temperature ◽  
Coupled Analysis ◽  
Outer Side ◽  
Fe Model ◽  
Alloy Plate ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Aluminum 7075

A 3D elastic-plastic and coupled thermo-mechanical FE model for friction stir welding(FSW) of aluminum 7075 plate with conical pin was developed based on the dynamic explicit code ABAQUS/explicit. Then temperature distribution and deformation behavior of 7075 aluminum alloy plate in FSW process were simulated and analyzed. The results show that the temperature is distributed in the plate with an approximate ellipse shape and decreases from the edge of the tool shoulder to the outer side of the plate. Furthermore, the maximum temperature zone decreases gradually from tool shoulder to the bottom of the plate. In the welding zone, the equivalent strain is also distributed with ring shapes, and it decreases from the edge of the tool shoulder to the outer side of the plate.

Effects of Heat Dissipation from Friction Stir Welding to Microstructures of Semi-Solid Cast 6063 Al Alloy

2021 ◽  
Vol 904 ◽  
pp. 70-75
Author(s):  
Chaiyoot Meengam ◽  
Kittima Sillapasa ◽  
Yotsakorn Pratumwal ◽  
Somboon Otarawanna
Keyword(s):  
Friction Stir Welding ◽  
Heat Dissipation ◽  
Maximum Temperature ◽  
Al Alloy ◽  
Element Analysis ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Measurement Results ◽  
6063 Al Alloy ◽  
Semi Solid

In this work, temperature distribution in semi-solid cast 6063 aluminum alloy workpieces during friction stir welding (FSW) was determined by finite element analysis (FEA). The FEA results were validated by comparing them with the measurement results from thermocouples. The maximum temperature of 534.2oC was predicted at the workpiece surface contacted with the tool shoulder. The temperature profiles obtained from FEA were used to explain microstructural changes during FSW. It was observed that relatively high temperature made α-Al grains became elongated and Mg2Si intermatalics turned into a rod-like morphology with round edges.

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

2011 ◽  
Vol 117-119 ◽  
pp. 1621-1624 ◽  
Author(s):  
Zheng Hua Guo ◽  
Gang Yao Zhao ◽  
Li Ming Ke ◽  
Li Xing ◽  
Shun Feng Zhu
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Flow Behavior ◽  
Fe Model ◽  
7075 Aluminum Alloy ◽  
Element Analysis ◽  
Alloy Plate ◽  
Friction Stir ◽  
Aluminum Alloy Plate ◽  
Materials Flow

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.

Effect of Axial Pressure and Tool Rotation Speed on Temperature Distribution during Dissimilar Friction Stir Welding

2011 ◽  
Vol 418-420 ◽  
pp. 1934-1938 ◽  
Author(s):  
R. Padmanaban ◽  
V. Balusamy ◽  
V. Ratna Kishore
Keyword(s):  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Rotation Speed ◽  
Maximum Temperature ◽  
Axial Pressure ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Shoulder ◽  
Dissimilar Aluminum Alloys ◽  
Tool Rotation

A computational fluid dynamics(CFD) based numerical model is developed to predict the temperature distribution during Friction Stir Welding(FSW) of dissimilar aluminum alloys. The effect of tool rotation speed and axial pressure on heat transfer during FSW has been studied. Numerical results indicate that the maximum temperature in FSW process can be increased with the increase of the axial pressure and tool rotation speed. The influence region of the tool shoulder in the direction of thickness can be increased with the increase in the axial pressure on the shoulder.

Friction stir welding of butt joints of 1420T1 and 1163T alloys sheets

2020 ◽  
pp. 446-453
Author(s):  
V.A. Berezina ◽  
V.V. Ovchinnikov ◽  
E.V. Luk’yanenko
Keyword(s):  
Friction Stir Welding ◽  
Ultimate Strength ◽  
Aluminium Alloys ◽  
Welded Joint ◽  
Butt Joint ◽  
Maximum Temperature ◽  
Butt Joints ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tool Rotation

The results of the butt joint formation of 5 mm thickness sheets from 1420T1 and 1163T aluminium alloys in different combination are presented. It is established that the ultimate strength of the joints depends on the location of the welded alloys relative to the direction of the tool rotation during friction stir welding. It is shown that depending on the location of 1420T1 and 1163T alloys on the side of the run in or out of the tool, the maximum temperature at the edge of the tool shoulder is 385 or 410 °C, in the weld core the metal is heated to 490 °C. The stir zone (the weld metal) consists of two zones corresponding to welded alloys without stir with each other. Ultimate strength to welded joint 1420T1 and 1163T alloys is 0.65...0.73 of ultimate strength to the 1420T1 alloy

scholarly journals A coupled thermo-mechanical model of friction stir welding

2012 ◽  
Vol 16 (2) ◽  
pp. 527-534 ◽  
Author(s):  
Darko Veljic ◽  
Milenko Perovic ◽  
Aleksandar Sedmak ◽  
Marko Rakin ◽  
Miroslav Trifunovic ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Plastic Strain ◽  
Mechanical Model ◽  
Temperature Fields ◽  
Maximum Temperature ◽  
Bottom Surface ◽  
Al Alloy ◽  
Fe Model ◽  
Arbitrary Lagrangian Eulerian ◽  
Friction Stir

A coupled thermo-mechanical model was developed to study the temperature fields, the plunge force and the plastic deformations of Al alloy 2024-T351 under different rotating speed: 350, 400 and 450 rpm, during the friction stir welding (FSW) process. Three-dimensional FE model has been developed in ABAQUS/Explicit using the arbitrary Lagrangian-Eulerian formulation, the Johnson-Cook material law and the Coulomb?s Law of friction. Numerical results indicate that the maximum temperature in the FSW process is lower than the melting point of the welding material. The temperature filed is approximately symmetrical along the welding line. A lower plastic strain region can be found near the welding tool in the trailing side on the bottom surface. With increasing rotation speed, the low plastic strain region is reduced. When the rotational speed is increased, the plunge force can be reduced. Regions with high equivalent plastic strains are observed which correspond to the nugget and the flow arm.

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

2011 ◽  
Vol 314-316 ◽  
pp. 346-350 ◽  
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.

A Thermo-Fluid Analysis of the Friction Stir Welding Process

2007 ◽  
Vol 539-543 ◽  
pp. 3832-3837 ◽  
Author(s):  
D. Jacquin ◽  
Christophe Desrayaud ◽  
Frank Montheillet
Keyword(s):  
Friction Stir Welding ◽  
Bulk Material ◽  
Welding Process ◽  
Vertical Motion ◽  
Velocity Fields ◽  
Fluid Simulation ◽  
Metal Sheet ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Fluid Analysis

The thermo-mechanical simulation of Friction Stir Welding focuses the interest of the welding scientific and technical community. However, literature reporting material flow modeling is rather poor. The present work is based on the model developed by Heurtier [2004] and aims at improving this thermo-fluid simulation developed by means of fluid mechanics numerical and analytical velocity fields combined together. These various velocity fields are investigated separately and especially according to the power dissipated during the flow. Boundary conditions are considered through a new approach based on the kinematic analysis of the thread of the pin. An equilibrium is established between the vertical motion of the bulk material dragged in the depth of the metal sheet, and its partial circulation around the pin. The analyses of the obtained velocity fields enable the understanding of the welded zone asymmetry and highlights the bulk material mixing between the welded coupons in the depth of the sheet. A regression is performed on the relative sliding velocity of the aluminium according to the surface of the tool: shoulder and pin. Two dimension flow lines in the depth of the metal sheet are then obtained and successfully compared with the results obtained by Colegrove (2004) [1].

scholarly journals Analysis of the tool plunge in friction stir welding - comparison of aluminium alloys 2024 T3 and 2024 T351

2016 ◽  
Vol 20 (1) ◽  
pp. 247-254
Author(s):  
Darko Veljic ◽  
Bojan Medjo ◽  
Marko Rakin ◽  
Zoran Radosavljevic ◽  
Nikola Bajic
Keyword(s):  
Friction Stir Welding ◽  
Plastic Strain ◽  
Heat Generation ◽  
Aluminium Alloys ◽  
Three Dimensional ◽  
Equivalent Plastic Strain ◽  
Fe Model ◽  
Arbitrary Lagrangian Eulerian ◽  
Friction Stir ◽  
Tool Pin

Temperature, plastic strain and heat generation during the plunge stage of the friction stir welding (FSW) of high-strength aluminium alloys 2024 T3 and 2024 T351 are considered in this work. The plunging of the tool into the material is done at different rotating speeds. A three-dimensional finite element (FE) model for thermomechanical simulation is developed. It is based on arbitrary Lagrangian-Eulerian formulation, and Johnson-Cook material law is used for modelling of material behaviour. From comparison of the numerical results for alloys 2024 T3 and 2024 T351, it can be seen that the former has more intensive heat generation from the plastic deformation, due to its higher strength. Friction heat generation is only slightly different for the two alloys. Therefore, temperatures in the working plate are higher in the alloy 2024 T3 for the same parameters of the plunge stage. Equivalent plastic strain is higher for 2024 T351 alloy, and the highest values are determined under the tool shoulder and around the tool pin. For the alloy 2024 T3, equivalent plastic strain is the highest in the influence zone of the tool pin.

scholarly journals 3D-Printed Tool Shoulder Design for the Analogue Modelling of Bobbin Friction Stir Weld Joint Quality

2021 ◽  
Vol 21 (1) ◽  
pp. 27-42
Author(s):  
A. Tamadon ◽  
D. J. Pons ◽  
K. Chakradhar ◽  
J. Kamboj ◽  
D. Clucas
Keyword(s):  
Friction Stir Welding ◽  
Cross Sections ◽  
Weld Joint ◽  
Flow Patterns ◽  
Friction Stir Weld ◽  
Butt Weld ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Analogue Modelling ◽  
3D Printed

Abstract A variety of tool shoulder designs comprising three families i.e. blade, spiral and circular shaped scrolls, were produced to improve the material flow and restrictions to avoid the tunnel void. The bobbin tools were manufactured by 3D printing additive manufacturing technology using solid filament. The butt weld joint was produced by each tool using plasticine as the workpiece material. The apparent surface features and bi-colour cross-sections provided a physical flow comparison among the shoulder designs. For the bobbin friction stir welding (BFSW), the tool shoulder with a three-spiral design produced the most stability with the best combination of the flow patterns on surface and cross-sections. The circular family tools showed a suitable intermixing on the surface pattern, while the blade scrolls showed better flow features within the cross-sections. The flow-driven effect of the shoulder features of the bobbin-tool design (inscribed grooves) was replicated by the 3D-printed tools and the analogue modelling of the weld samples. Similar flow patterns were achieved by dissimilar aluminium-copper weld, validating the accuracy of the analogue plasticine for the flow visualization of the bobbin friction stir welding.

Effects of Tool Pin Profile and Tool Shoulder Diameter on the Tensile Behaviour of Friction Stir Welded Joints of Aluminium Alloys

2014 ◽  
Vol 984-985 ◽  
pp. 586-591 ◽  
Author(s):  
R. Ashok Kumar ◽  
M.R. Thansekhar
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Tensile Properties ◽  
Welded Joints ◽  
Tensile Behaviour ◽  
Light Weight ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Weight Structures

— For fabricating light weight structures, it requires high strength-to weight ratio. AA6061 aluminium alloy is widely used in the fabrication of light weight structures. A356 aluminium alloy has wide spread application in aerospace industries. Friction stir welding is solid state joining process which is conducting for joining similar and dissimilar materials. The friction stir welding parameters play an important role for deciding the strength of welded joints. In this investigation, A356 and AA6061 alloys were friction stir welded by varying triangular, square, hexagonal pin profiles of tool keeping the remaining parameters same and AA6061 alloys were friction stir welded by varying tool shoulder diameter as 12mm,15mm,18mm without changing other parameters. Tensile properties of each joint have been analyzed microscopically. From the experimental results, it is observed that hexagonal pin profiled tool and 15mm shoulder diameter tool provides higher tensile properties when compared to other tools.

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