Heat Generation Performance of a Homemade Friction Stir Welding Tool

2014 ◽  
Vol 903 ◽  
pp. 200-205
Author(s):  
Irfan Hilmy ◽  
Erry Yulian Triblas Adesta ◽  
Muhammad Riza
Keyword(s):  
Experimental Investigation ◽  
Friction Stir Welding ◽  
Heat Generation ◽  
Element Model ◽  
Heat Transfer Analysis ◽  
Work Piece ◽  
Generation Model ◽  
Friction Stir ◽  
The One ◽  
Fsw Parameters

Friction Stir Welding (FSW) is getting its popularity because it is considered as an environmentally friendly manufacturing. Homemade FSW tool to be attached to a conventional milling machine was designed and fabricated. Experimental investigation of FSW process of the Aluminum alloy work piece to observe its heat generation was performed. Since heat generation is the main objective in a FSW process, the importance of identification of heat generation performance in a welded specimen is paramount. Heat generation of a welded specimen during FSW was measured using infra red thermal camera. The limitation of the measurement is it only captured the heat generation at surrounding area and surface of the welded specimen. Therefore, the heat generation inside contact area could not be identified. To overcome this problem, a finite-element model of the FSW process was developed. A model consists of a solid model of half the welded specimen since the symmetrical behavior of the geometry and boundary condition was assumed. Heat transfer analysis of a solid body model of a work piece was computed. It was observed that FSW parameters which involved dominantly in the heat generation were spindle speed, feeding rate and normal force. The heat generation model of FSW process was validated with the one from the experimental investigation. Good agreement between the numerical and the experimental investigation result has been made.

scholarly journals Thermo-mechanical analysis of linear welding stage in friction stir welding - influence of welding parameters

2021 ◽  
pp. 186-186
Author(s):  
Darko Veljic ◽  
Marko Rakin ◽  
Aleksandar Sedmak ◽  
Nenad Radovic ◽  
Bojan Medjo ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Heat Generation ◽  
Welding Speed ◽  
Reaction Force ◽  
Material Model ◽  
Element Model ◽  
Welding Parameters ◽  
Al Alloy ◽  
Friction Stir ◽  
Fsw Parameters

The influence of friction stir welding (FSW) parameters on thermo-mechanical behaviour of the material during welding is analysed. An aluminium alloy is considered (Al 2024 T351), and different rotating speed and welding speed are applied. Finite element model consists of the plate (Al alloy), backing plate and welding tool, and it is formed and solved in software package Simulia Abaqus. The influence of the welding conditions on material behaviour is taken into account by application of the Johnson-Cook material model. The rotation of the tool affects the results: if increased, it contributes to an increase of friction-generated heat intensity. The other component of the generated heat, the plastic deformation of the material, is negligibly changed. When the welding speed is increased, the intensity of friction-generated heat decreases, while the heat generation due to plastic deforming increases. Combined, these two effects cause small change of the total heat generation. For the same welded joint length, the plate welded by lower speed will be heated more intensively. The changes of the heat generation influence both the temperature field and reaction force, which are also considered.

Numerical Analysis of Multi-Field Coupled Phenomena in Friction Stir Welding and Applications

2014 ◽  
Vol 783-786 ◽  
pp. 1794-1807
Author(s):  
Qing Yu Shi ◽  
Gao Qiang Chen ◽  
Xi Bo Wang ◽  
Xu Kang
Keyword(s):  
Numerical Simulation ◽  
Friction Stir Welding ◽  
Heat Generation ◽  
Material Flow ◽  
Metal Flow ◽  
Friction Stir ◽  
Rate Dependent ◽  
Potential Applications ◽  
Complex Phenomena ◽  
Fsw Parameters

Friction stir welding (FSW) is an advanced solid state joining technology, which was invented by TWI in 1991. During the process, large amount of heat is generated due to the friction between the tool and the material. As a result, the metal around the tool is softened as the temperature rises, and significant plastic flow occurs. So FSW is a complex process with multi-field coupled phenomena. Material flow plays a central role in FSW. But it is still difficult to reveal the material flow regime and joining mechanism during FSW process. Numerical simulation is a powerful tool for investigating the metal-flow-related complex phenomena during FSW. Meanwhile, numerical simulation could also help to optimize FSW tool design and FSW parameters. In this paper, we review the recent development in simulation of material flow during FSW. Then, the important issues in modeling multi field coupled phenomena during FSW are summarized, which include the heat generation mechanism, the temperature and strain rate dependent material’s behavior, and the interaction between tool and material. Finally, a comprehensive simulation model is presented, which enables advanced study on the coupled phenomena of heat generation, temperature distribution, material flow, and defects formation. This model has shown potential applications in simulating the relation between the transport of material and the macrostructure formation or defects formation. In spite of these progresses, simulation of material flow during FSW still need quite a lot of researches to fulfill industry requirement.

A Numerical and Experimental Analysis of Microstructural Aspects in AA2024-T3 Friction Stir Welding

2013 ◽  
Vol 554-557 ◽  
pp. 1022-1030 ◽  
Author(s):  
Pierpaolo Carlone ◽  
Gaetano S. Palazzo
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Heat Generation ◽  
Process Parameters ◽  
Fluid Dynamic ◽  
Weld Line ◽  
Work Piece ◽  
Viscoplastic Material ◽  
Influence Of Process Parameters ◽  
Friction Stir

In recent years, remarkable interest has been focused on the Friction Stir Welding (FSW) process, by academic as well as industrial research groups. Conceptually, the FSW process is quite simple: a non-consumable rotating tool is plunged between the adjoining edges of the parts to be welded and moved along the desired weld line. Frictional and viscous heat generation increases the work piece temperature, softening the processing material and forcing it to flow around the pin. Although FSW has been effectively applied in welding of several materials, such as copper, steel, magnesium, and titanium, considerable attention is still focused on aluminum welding, in particular for transport applications. Recent literature clearly evidenced microstructural variations in the stir zone, imputable to continuous dynamic recrystallization phenomena, leading to the formation of a finer equiaxed grains. Moreover, depending on the specific alloy, thermal cycles can induce coarsening or dissolution of precipitates in the thermo-mechanically affected zone (TMAZ) and in the heat affected zone (HAZ). The influence of the aforementioned microstructural aspects on mechanical properties and formability of FSWed assemblies is also well recognized. The aim of this paper is to numerically and experimentally investigate the influence of process parameters, namely rotating speed and welding speed, on microstructural aspects in AA2024-T3 friction stir butt welds. A three-dimensional Computational Fluid Dynamic (CFD) model has been implemented to simulate the process. A viscoplastic material model, based on Wright and Sheppard modification of the constitutive model initially proposed by Sellars and Tegart has been implemented in the commercial package ANSYS CFX, considering an Eulerian framework. Tool-workpiece interaction has been modeled assuming partial sticking/sliding condition, and incorporating both frictional and viscous contributions to the heat generation. Microstructural aspects have been numerically predicted using the Zenner-Holloman parameter and experimentally measured by means of conventional metallographic techniques. Satisfactory agreement has been found between simulated and experimental results. The influence of process parameters on mechanical properties has also been highlighted.

scholarly journals Heat generation during plunge stage in friction stir welding

2013 ◽  
Vol 17 (2) ◽  
pp. 489-496 ◽  
Author(s):  
Darko Veljic ◽  
Marko Rakin ◽  
Milenko Perovic ◽  
Bojan Medjo ◽  
Zoran Radakovic ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Heat Generation ◽  
Slip Rate ◽  
Element Model ◽  
Numerical Results ◽  
Frictional Heat ◽  
Al Alloy ◽  
Arbitrary Lagrangian Eulerian ◽  
Workpiece Material ◽  
Friction Stir

This paper deals with the heat generation in the Al alloy Al2024-T3 plate under different rotating speeds and plunge speeds during the plunge stage of friction stir welding (FSW). A three-dimensional finite element model (FEM) is developed in the commercial code ABAQUS/Explicit using the arbitrary Lagrangian-Eulerian formulation, the Johnson-Cook material law and Coulomb?s Law of friction. The heat generation in FSW can be divided into two parts: frictional heat generated by the tool and heat generated by material deformation near the pin and the tool shoulder region. Numerical results obtained in this work indicate a more prominent influence from the friction-generated heat. The slip rate of the tool relative to the workpiece material is related to this portion of heat. The material velocity, on the other hand, is related to the heat generated by plastic deformation. Increasing the plunging speed of the tool decreases the friction-generated heat and increases the amount of deformation-generated heat, while increasing the tool rotating speed has the opposite influence on both heat portions. Numerical results are compared with the experimental ones, in order to validate the numerical model, and a good agreement is obtained.

scholarly journals Bobbin Tool Friction Stir Welding of Aluminum Using Different Tool Pin Geometries: Mathematical Models for the Heat Generation

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 438
Author(s):  
Mohamed M. Z. Ahmed ◽  
Mohamed I. A. Habba ◽  
Nabil Jouini ◽  
Bandar Alzahrani ◽  
Mohamed M. El-Sayed Seleman ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Mathematical Models ◽  
Heat Generation ◽  
Friction Stir ◽  
Joint Quality ◽  
Fsw Parameters ◽  
Tool Pin ◽  
Fsw Experiments ◽  
Tool Rotation ◽  
Good Agreement

In this work, three mathematical models for the heat generation during bobbin tool friction stir welding (BT-FSW) of aluminum using three tool pin geometries have been proposed. The models have utilized and updated the available models for the heat generation during the conventional tool friction stir welding (CT-FSW). For the validation of the models, BT-FSW experiments have been carried out for aluminum alloy AA1050 using three different pin geometries (cylindrical, square, and triangular), at different welding speeds of 200, 400, 600, 800, and 1000 mm/min and a constant tool rotation speed of 600 rpm. The welding temperatures during BT-FSW have been measured to be compared with that calculated from the models at the same parameters. It has been found that the calculated welding temperatures from the models and that measured during BT-FSW are in good agreement at all the investigated welding speeds especially in case of the square and cylindrical pins, proving the validity of the developed models for the predication of the heat generation as well as the welding temperatures. This will allow proper designing of the BT-FSW parameters and avoiding the conditions that can deteriorate the joint quality and properties.

scholarly journals Experimental Investigation and Optimization on Friction Stir Welding of Nylon 6A Using Taguchi and ANOVA with Microstructural Analysis

2021 ◽  
Vol 2021 ◽  
pp. 1-12
Author(s):  
G. S. V. Seshu Kumar ◽  
Anshuman Kumar ◽  
S. Rajesh ◽  
Rama Bhadri Raju Chekuri ◽  
Amsalu Gosu Adigo
Keyword(s):  
Experimental Investigation ◽  
Friction Stir Welding ◽  
Feed Rate ◽  
Optimization Technique ◽  
Microstructural Analysis ◽  
Composite Plates ◽  
Friction Stir ◽  
Operating Process ◽  
Environmentally Friendly Process ◽  
Fsw Parameters

Friction stir welding is an environmentally friendly process of joining due to the nonusage of flux, or any shield gas, and it does not produce any harmful gases when compared to the joining process of fusion. Therefore, this article proposes an experimental investigation and optimization technique for studying the process of FSW on nylon 6A or polycaprolactam polymer composite plates. Specifically, the influence of input operating process parameters such as tool rotational speed (TRS), feed rate, and pitch values on the output response parameters like ultimate tensile strength (UTS) and hardness of welded joints is examined. In addition, L27 orthogonal array of Taguchi approach is employed for the optimization of design experiments of FSW parameters. The experimental setup is carried out with various process parameter combinations like 500 rpm, 1000 rpm, and 1500 rpm as TRS, and 30 mm, 40 mm, and 50 mm as feed rate by varying the pitch values as 1 mm, 2 mm, and 3 mm. Further, the analysis of variance (ANOVA) is also employed for finding the significant parameters of input process using the regression analysis equations. Finally, microstructural analysis is used to assess the mixing or dispersing uniformity of composites effectively.

Microstructure and Mechanical Properties at the Unsteady Areas of Non-Linear Friction Stir Welding

2007 ◽  
Vol 561-565 ◽  
pp. 1059-1062 ◽  
Author(s):  
H. Takahara ◽  
Masato Tsujikawa ◽  
Sung Wook Chung ◽  
Y. Okawa ◽  
Kenji Higashi
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welding Parameter ◽  
Butt Joints ◽  
Friction Stir ◽  
Non Linear ◽  
Linear Friction ◽  
Fsw Parameters ◽  
Five Axis ◽  
Welding Direction

The influence of tool control in non-linear friction stir welding (FSW) on mechanical properties of joints was investigated. FSW is widely applied to linear joints. It is impossible for five axis FSW machines, however, to keep all the FSW parameters in optimum conditions at non-linear welding. Non-linear FSW joints should be made by compromise with the order of priority for FSW parameters. The tensile test results of butt joints with rectangular change in welding direction on plate plane (L-shaped butt joints) with various welding parameter change. It was found that turn to the retreating side is encouraged when welding direction change. And the method of zero inclination tool angle is effective at non-linear and plane welding.

Effect of plasma preheating on weld quality and tool life during friction stir welding of DH36 steel

2021 ◽  
pp. 095440542199013
Author(s):  
Avinish Tiwari ◽  
Pardeep Pankaj ◽  
Saurav Suman ◽  
Piyush Singh ◽  
Pankaj Biswas ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Tool Life ◽  
Force Measurement ◽  
Deep Understanding ◽  
High Strength ◽  
Microstructural Characterization ◽  
Stir Zone ◽  
Friction Stir ◽  
Allotriomorphic Ferrite ◽  
Fsw Parameters

Friction stir welding (FSW) of high strength materials is challenging due to high tool cost and low tool life. To address this issue, the present investigation deals with an alternative of plasma-assisted friction stir welding (PFSW) of DH36 steel with WC-10%Co tool. Plasma preheating current (13 A, 15 A, and 17 A) was varied by keeping other FSW parameters as constant. During the FSW and PFSW process, force measurement and thermal history aided in a deep understanding of the process, tool degradation mechanisms, accompanied by the mechanical and microstructural characterization of the welded joints. The stir zone hardness was increased from 140 HV0.5 to about 267 HV0.5. The yield and tensile strength of weld increased from 385 MPa and 514 MPa to about 391 MPa and 539 MPa, respectively. Weld joint elongation (%) was increased from ~10% of weld 1 to ~13.89% of weld 4. During PFSW, the process temperature was increased, the cooling rate was lowered, and the weld bead was widened. The results also revealed that the plasma-assisted weld resulted in polygonal ([Formula: see text]) and allotriomorphic ferrite as the major constituents in the stir zone. Pearlite dissolution and spheroidization were observed in the ICHAZ and SCHAZ, respectively. Additionally, the plasma preheating reduced the tungsten tool’s wear by 58% compared to FSW.

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