MODELING OF HEAT ENERGIES AND FORCES IN FRICTION STIR WELDING (original) (raw)
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Materials Science
The paper analyzes the problem of friction stir welding (FSW) technology. The mechanism of thermo-mechanical process of the FSW method has been identified and a correlation between the weld zone and its microstructure established. Presented are the basic analytical formulations for the definition of temperature fields. Analysis of influential parameters of welding FSW technology at the zone of the weld material and mechanical properties of the realized joint was performed. Influential welding parameters were defined based on tool geometry, technological parameters of processing and the axial load of tool. Specific problems with the FSW process are related to gaps (holes) left behind by a tool at the end of the process and inflexibility of welding regarding the degree of variation of material thickness. Numerical simulation of process welding FSW proceeding was carried out on the example of Aluminum Alloy (AA 2219) using the ANSYS Mechanical ADPL (Transient Thermal) software package. The defined was the temperature field in the welding process at specified time intervals.
Thermal Science, 2021
The influence of friction stir welding (FSW) parameters on thermomechanical 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 s...
Journal of The Institution of Engineers (India): Series C, 2016
Friction stir welding (FSW) has been the most attracting solid state welding process as it provides better mechanical and metallurgical properties of the weld. Non-weldable alluminium alloys like 5XXX, 7XXX series can be welded by this process without any difficulty. The butt welding is done using two thin plates (200mm × 100mm × 6mm) of similar metals, i.e, alluminium alloys of grade AA1100. The tool material was made of stainless steel (SS-310 tool steel). In the present study, the traverse speed of the tool was kept constant while four different types of tool geometry, two different rotational speed of the tool alongwith two different plunging forces were used. Thus, a set of eight experiments were conducted and mechanical properties like micro-hardness and tensile strength of the welded specimens have been studied for different process parameters settings. Also, a mathematical model is developed to estimate the generated heat in the welding zone. It was noticed that friction is the major contributor for the heat generation. It was observed that the tool rotational speed and traverse speed have varying effects on tensile strength and hardness of FSWed joints. An attempt is also made to validate the theoretical model of the heat generation in the FSW process.
Finite element modeling of friction stir welding--thermal and thermomechanical analysis
International Journal of Machine Tools and …, 2003
Friction stir welding (FSW) is a relatively new welding process that may have significant advantages compared to the fusion processes as follow: joining of conventionally non-fusion weldable alloys, reduced distortion and improved mechanical properties of weldable alloys joints due to the pure solid-state joining of metals. In this paper, a three-dimensional model based on finite element analysis is used to study the thermal history and thermomechanical process in the butt-welding of aluminum alloy 6061-T6. The model incorporates the mechanical reaction of the tool and thermomechanical process of the welded material. The heat source incorporated in the model involves the friction between the material and the probe and the shoulder. In order to provide a quantitative framework for understanding the dynamics of the FSW thermomechanical process, the thermal history and the evolution of longitudinal, lateral, and through-thickness stress in the friction stirred weld are simulated numerically. The X-ray diffraction (XRD) technique is used to measure the residual stress of the welded plate, and the measured results are used to validate the efficiency of the proposed model. The relationship between the calculated residual stresses of the weld and the process parameters such as tool traverse speed is presented. It is anticipated that the model can be extended to optimize the FSW process in order to minimize the residual stress of the weld.
Acta Metallurgica Sinica (English Letters), 2016
Friction stir welding (FSW) is a solid-state joining process, where joint properties largely depend on the amount of heat generation during the welding process. The objective of this paper was to develop a numerical thermomechanical model for FSW of aluminum-copper alloy AA2219 and analyze heat generation during the welding process. The thermomechanical model has been developed utilizing ANSYS Ò APDL. The model was verified by comparing simulated temperature profile of three different weld schedules (i.e., different combinations of weld parameters in real weld situations) from simulation with experimental results. Furthermore, the verified model was used to analyze the effect of different weld parameters on heat generation. Among all the weld parameters, the effect of rotational speed on heat generation is the highest.
International Journal of Engineering Research and Technology (IJERT), 2016
https://www.ijert.org/thermomechanical-modeling-of-friction-stir-welding-for-different-material-using-altairs-hyperweld-fsw https://www.ijert.org/research/thermomechanical-modeling-of-friction-stir-welding-for-different-material-using-altairs-hyperweld-fsw-IJERTV4IS120001.pdf Friction stir welding (FSW) is a solid state welding process which involves the joining of two similar or dissimilar materials without the application of filler material. The tool performs the three steps to complete the welding process which are Plunge, Dwell and Translation. During the plunge stage the tool penetrates into the workpiece material and then translates onto the weld line. In between the translation motion tool moves in forward direction and behind that the workpiece material mixed into each other and form weld. In this paper study, Friction stir welding is a nonlinear thermal process which is simulate with the help of using Altair's HyperWeld. It is foremost computer-aided engineering (CAE) application which used in simulation purpose. Using different materials with different input parameters the butt joint is created. In this study the different materials are used such as AA7075, AA6061, and AA2219 for various process parameters. The process parameters are (1) Rotational speed are 600 rpm, 1000 rpm and 1400 rpm, (2) Tool translational speed are 100 mm/min, 150mm/min and 200 mm/min and (3) Tool shoulder diameter are 12 mm, 18 mm and 24mm. With the help of these different process and geometrical parameters the thermal distribution result is analyzed. The results are presented for dissimilarity in peak temperature of three different aluminum alloy plate at the same input parameters during the Friction Stir Welding process.
A Review of Friction Stir Welding Process and its Variables
2013
Friction Stir Welding (FSW) was invented by Wayne Thomas at TWI (The Welding Institute), and the first patent applications were filed in the UK in December 1991. Initially, the process was regarded as a “laboratory” curiosity, but it soon became clear that FSW offers numerous benefits in the fabrication of aluminum products. Friction Stir Welding (FSW) has become a major joining process in the aerospace, railway and ship building industries especially in the fabrication of aluminum alloys. The process uses a spinning non-consumable tool to generate frictional heat in the work piece. Worldwide, there are now over 135 licensees of FSW and new techniques and applications are being developed daily. This paper looks at the review, on friction stir welding process, various welding variables like tool rotation, transverse speed, tool tilt, plunge depth and tool design, for the welding of aluminum alloys or various dissimilar alloys. Applications, future aspects and several key problems are...
A thermal model of friction stir welding in aluminum alloys
International Journal of Machine Tools and Manufacture, 2008
A thermal model of friction stir welding was developed that utilizes a new slip factor based on the energy per unit length of weld. The slip factor is derived from an empirical, linear relationship observed between the ratio of the maximum welding temperature to the solidus temperature and the welding energy. The thermal model successfully predicts the maximum welding temperature over a wide range of energy levels but under predicts the temperature for low energy levels for which heat from plastic deformation dominates. The thermal model supports the hypothesis that the relationship between the temperature ratio and energy level is characteristic of aluminum alloys that share similar thermal diffusivities. The thermal model can be used to generate characteristic temperature curves from which the maximum welding temperature in an alloy may be estimated if the thermal diffusivity, welding parameters and tool geometry are known.
Numerical modeling of friction stir welding process: a literature review
The International Journal of Advanced Manufacturing …, 2012
This survey presents a literature review on friction stir welding (FSW) modeling with a special focus on the heat generation due to the contact conditions between the FSW tool and the workpiece. The physical process is described and the main process parameters that are relevant to its modeling are highlighted. The contact conditions (sliding/sticking) are presented as well as an analytical model that allows estimating the associated heat generation. The modeling of the FSW process requires the knowledge of the heat loss mechanisms, which are discussed mainly considering the more commonly adopted formulations. Different approaches that have been used to investigate the material flow are presented and their advantages/drawbacks are discussed. A reliable FSW process modeling depends on the fine tuning of some process and material parameters. Usually, these parameters are achieved with base on experimental data. The numerical modeling of the FSW process can help to achieve such parameters with less effort and with economic advantages.