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.

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.

scholarly journals FSW Numerical Simulation of Aluminium Plates by SYSWELD - Part II

2016 ◽  
Vol 66 (2) ◽  
pp. 29-36 ◽  
Author(s):  
Roland Jančo ◽  
Ladislav Écsi ◽  
Pavel Élesztős
Keyword(s):  
Numerical Simulation ◽  
Material Flow ◽  
Complex Interaction ◽  
Fluid Simulation ◽  
Stress And Strain ◽  
The Finite Element Method ◽  
Friction Stir ◽  
Simulation Process ◽  
Potential Applications ◽  
Solid State Joining

Abstract Friction Stir Welding (FSW) is one of the most effective solid state joining processes and has numerous potential applications in many industries. The simulation process can provide the evolution of physicals quantities such as temperature, metallurgical phase proportions, stress and strain which can be easily measured during welding. The numerical modelling requires the modelling of the complex interaction between thermal, metallurgical and mechanical phenomena. The aim of this paper is to describe the thermal-fluid simulation of FSW using the finite element method. In the theoretical part of paper heating is provided by the material flow and contact condition between the tool and the welded material. Thermal-mechanical results from the numerical simulation using SYSWELD are also presented for aluminium alloy.

scholarly journals FSW Numerical Simulation of Aluminium Plates by Sysweld - Part I

2016 ◽  
Vol 66 (1) ◽  
pp. 47-52 ◽  
Author(s):  
Roland Jančo ◽  
Ladislav Écsi ◽  
Pavel Élesztős
Keyword(s):  
Numerical Simulation ◽  
Material Flow ◽  
Fluid Simulation ◽  
Stress And Strain ◽  
The Finite Element Method ◽  
Friction Stir ◽  
Simulation Process ◽  
Potential Applications ◽  
Solid State Joining ◽  
Physical Quantities

AbstractFriction Stir Welding (FSW) is one of the most effective solid state joining processes and it has numerous potential applications in many industries. The simulation process can provide the evolution of physical quantities such as temperature, metallurgical phase proportions, stress and strain which can be easily measured during welding. The numerical modelling requires the modelling of a complex interaction between thermal, metallurgical and mechanical phenomena. The aim of this paper is to describe the thermal-fluid simulation of FSW using the finite element method. In the theoretical part of the paper heating is provided by the material flow and contact condition between the tool and the welded material. The thermal-fluid results from the numerical simulation for aluminium alloy using SYSWELD are also presented in this paper.

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.

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