Thermo-Mechanical Modelling of Jointing Process by Friction Stir Welding of Aluminium-Based Composite Materials

2012 ◽  
Vol 188 ◽  
pp. 144-149
Author(s):  
Marius Pop-Calimanu ◽  
Traian Fleșer
Keyword(s):  
Composite Materials ◽  
Friction Stir Welding ◽  
High Speed ◽  
Active Element ◽  
Three Dimensional ◽  
Maximum Temperature ◽  
Friction Stir ◽  
Thermal Fields ◽  
Welding Defects ◽  
Dimensional Distribution

Jointing with rotary active element gains field through technological facilities offered nowadays. Own research have developed a model for studying the thermal fields and the plastic deformations of jointing composite materials Al/20%SiC combined by friction stir welding (FSW). In this article we will present the three-dimensional distribution of investigated fields, correlated with input parameters in the process. The process is performed with solid state components. The numerical results indicate that the maximum temperature in the FSW process increases with increasing speed of rotational tools. For high speed welding joint, should be increased, at the same time, the rotational speed to avoid welding defects.

High Speed Friction Stir Welding: A Computational and Experimental Study

2005 ◽  
Author(s):  
Harsha Raikoty ◽  
Ikram Ahmed ◽  
George E. Talia
Keyword(s):  
Friction Stir Welding ◽  
Thermal Model ◽  
High Speed ◽  
Three Dimensional ◽  
Weld Line ◽  
Infrared Camera ◽  
Processing Conditions ◽  
Moving Heat Source ◽  
Friction Stir ◽  
Numerical Predictions

A three-dimensional numerical analysis of friction stir welding at high speed (HS-FSW) is presented here. The temperature distribution in the workpiece has been calculated for a number of processing conditions. The analysis adopts a thermal model based on the simple laws of friction. This model translates to having a moving heat source along the weld-line on the top surface of the workpieces. Results have been validated experimentally using an infrared camera as well as thermocouple measurements. By comparing actual welds performed on Aluminum 6061-T6 and the numerical predictions, it is observed that the appropriate range for the (maximum) surface temperatures for obtaining a sound weld is between 570°C and 530°C, and that these temperatures are achieved between spindle translation velocities of 125 mm/min and 250 mm/min, respectively.

Dimensional Analysis of Thermal Fields Surrounding Friction Stir Welding Process

2014 ◽  
Author(s):  
Lewis N. Payton ◽  
Vishnu Vardhan Chandrasekaran ◽  
Wesley S. Hunko
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Temperature Fields ◽  
Analytical Comparison ◽  
Friction Stir ◽  
Thermal Fields ◽  
Designed Experiment ◽  
Pi Theorem ◽  
Alloy 6061

A dimensionless correlation is developed based on Buckingham’s Pi-Theorem to estimate the temperature fields generated by the movement of a tool during the Friction Stir Welding of an aluminum alloy (6061-T6). Symmetrical thermocouple measurements are taken during a statistically designed experiment using different factor levels (RPM, Traverse, etc). Analytical comparison (using multivariate ANOVA) validates the predicted dimensionless correlation including the often-reported difference between the advancing versus retreating side of the Friction Stir Tool.

Volumetric defect analysis in friction stir welding based on three dimensional reconstructed images

2017 ◽  
Vol 29 ◽  
pp. 96-112 ◽  
Author(s):  
Chirag Parikh ◽  
Ravi Ranjan ◽  
Aaquib Reza Khan ◽  
Rahul Jain ◽  
Raju Prasad Mahto ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Three Dimensional ◽  
Defect Analysis ◽  
Friction Stir

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 High Quality-High Speed Friction Stir Welding of 304 Austenitic Stainless Steel

2008 ◽  
Vol 94 (11) ◽  
pp. 539-544 ◽  
Author(s):  
Takeshi Ishikawa ◽  
Hidetoshi Fujii ◽  
Kazuo Genchi ◽  
Shunichi Iwaki ◽  
Shigeki Matsuoka ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Friction Stir Welding ◽  
Austenitic Stainless Steel ◽  
High Speed ◽  
High Quality ◽  
Friction Stir ◽  
304 Austenitic Stainless Steel

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.

scholarly journals Innovate Method for Friction Stir Welding of Al-Mg-Si Alloy Thin Plate

2019 ◽  
Vol 269 ◽  
pp. 02006
Author(s):  
Li Fu ◽  
Fenjun Liu
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Base Metal ◽  
High Speed ◽  
Thick Plate ◽  
Welding Parameters ◽  
Butt Joints ◽  
Friction Stir ◽  
High Rotation Speed ◽  
Precipitated Phases

Al-Mg-Si (6061-T6) alloy with 0.8 mm thick plate was welded successfully by use of high speed friction stir welding (FSW) technology. The microstructural characteristics and mechanical property of the butt joints prepared by high speed FSW were analyzed in detail, the influence of welding parameters, fixture condition and after welding heat treatment were also explored. The results shown that sound surface topography and defect-free bonding interface were observed in the nugget zone (NZ). The microhardness of the as-welded joint was lower than that of the base metal because of the welding heat effect. Compared with the conventional speed FSW, the number of β-Mg2Si, Al2CuMg and Al8Fe2Si precipitated phases existed in the high speed FSWed NZ increased, which made the microhardness in the NZ improved significantly. The rod-shaped precipitates (Mg2Si) have the greatest influence on the microhardness distributions. The maximum tensile strength of 301.8 MPa, which was 85.8% of the base metal, was obtained at high rotation speed of 8000 rpm and fast welding speed of 1500 mm/min. The tensile strength of the ultra-high speed FSWed butt joints were improved significantly by post-weld artificial aging, with a maximum joint efficiency of 90.4%.

Sign in / Sign up

Export Citation Format

Share Document