Numerical and Experimental Investigations on the Loads Carried by the Tool During Friction Stir Welding
Source abstract
Abstract
A computational fluid dynamics (CFD) model is presented for simulating the material flow and heat transfer in the friction stir welding (FSW) of 6061-T6 aluminum alloy (AA6061). The goal is to utilize the 3-D, numerical model to analyze the viscous and inertia loads applied to the FSW tool by varying the welding parameters. To extend the FSW process modeling, in this study, the temperature-dependant material properties as well as the stick/slip condition are considered where the material at the proximity of the FSW tool slips on the lower pressure regions. A right-handed one-way thread on a tilted FSW tool pin with a smooth, concaved shoulder is, additionally, considered to increase the accuracy of the numerical model. In addition, the viscous and frictional heating are assumed as the only sources of heat input. In the course of model verification, good agreements are found between the numerical results and the experimental investigations.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Advanced Welding Techniques Analysis · Aluminum Alloys Composites Properties · Aluminum Alloy Microstructure Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (38)
Show source-provided references
1. W.M. Thomas, E.D. Nicholas, J.C. Needham, M.G. Murch, P.T. Smith, and C.J. Dawes, International Patent No. PCT/GB92/02203, GB Patent No. 9125978.8 (1991), US Patent No. 5,460,317 (1995)
2. J.H. Ouyang and R. Kovacevic, 2002 Material Flow and Microstructure in the Friction Stir Butt Welds of the Same and Dissimilar Aluminum Alloys, J. Mater. Eng. Perfom. 11(1), 51–6310.1007/s11665-002-0008-0 ↗
3. W.J. Arbegast, 2006 Friction Stir Welding After a Decade of Development, Weld. J., 85(3), 28–35
4. H.R. Shercliff, J. Michael, M.J. Russell, A. Taylor, and T.L. Dickerson, 2005 Microstructural Modeling in Friction Stir Welding of 2000 Series Aluminum Alloys, Mec. Indust., 6, 25–35
5. Y.S. Sato, S·H. Park, and H. Kokawa, 2001 Microstructural Factors Governing Hardness in Friction Stir Welds of Solid-Solution-Hardened Al Alloys, Metall. Mater. Trans. A, 32, 303310.1007/s11661-001-0178-7 ↗
6. T.J. Lienert, W.L. Stellwag, B.B. Grimmett, and R.W. Warke, Friction Stir Welding Studies on Mild Steel, Weld. J., 2003, p 1–9
7. P.A. Colegrove, H.R. Shercliff 2004 Development of Trivex Friction Stir Welding Tool, Part 1—Two-Dimensional Flow Modeling and Experimental Validation, Sci. Technol. Weld. Join., 9(4), 345–35110.1179/136217104225021670 ↗
8. Y.J. Chao, X. Qi, W. Tang 2003 Heat Transfer in Friction Stir Welding—Experimental and Numerical Studies, J. Manuf. Sci. Eng., 125, 138–14510.1115/1.1537741 ↗
9. P. Heurtier, M.J. Jones, C. Desrayaud, J.H. Driver, F. Montheillet, and D. Allehaux, 2006 Mechanical and Thermal Modeling of Friction Stir Welding, J. Mater. Process. Technol., 171, 348–35710.1016/j.jmatprotec.2005.07.014 ↗
10. M. Guerra, C. Schmidt, J.C. McClure, L.E. Murr, A.C. Nunes 2003 Flow Patterns During Friction Stir Welding, Mater. Charact., 49, 95–10110.1016/S1044-5803(02)00362-5 ↗
11. B. London, M. Mahoney, W. Bingel, M. Calabrese, and D. Waldron, Experimental Methods for Determining Material Flow in Friction Stir Welds, Presented at the 3rd International Symposium on Friction Stir Welding (Kobe, Japan), Sep 2001, p 4–7
12. K. Colligan 1999 Material Flow Behavior During Friction Stir Welding of Aluminum, Weld. J., 75(7), 229–237
13. L. Ke, X. Li, and J.E. Indacochea 2004 Material Flow Patterns and Cavity Model in Friction-Stir Welding of Aluminum Alloys, Metall. Mater. Trans. B, 35, 153–16010.1007/s11663-004-0105-6 ↗
14. T.U. Seidel and A.P. Reynolds 2001 Visualization of Material Flow in AA2195 Friction Stir Welds Using a Marker Insert Technique, Metall. Mater. Trans. A, 37, 2879–288410.1007/s11661-001-1038-1 ↗
15. P.A. Colegrove and H.R. Shercliff, 2005. 3-Dimensional CFD Modelling of Flow Round a Threaded Friction Stir Welding Tool Profile, J. Mater. Process. Technol., 169, 320–32710.1016/j.jmatprotec.2005.03.015 ↗
16. R. Nandan, G.G. Roy, T. DebRoy 2006 Numerical Simulation of Three-Dimensional Heat Transfer and Plastic Flow During Friction Stir Welding, Metall. Mater. Trans. A, 37, 1247–125910.1007/s11661-006-1076-9 ↗
17. S. Xu, X. Deng, A.P. Reynolds, and T.U. Seidel, 2001 Finite Element Simulation of Material Flow in Friction Stir Welding, Sci. Technol. Welding Joining, 6(3), 191–19310.1179/136217101101538640 ↗
18. R. Crawford, G.E. Cook, A.M. Strauss, D.A. Hartman, and M.A. Stremler 2006. Experimental Defect Analysis and Force Prediction Simulation of High Weld Pitch Friction Stir Welding, Sci. Technol. Welding Joining, 11(6), 657–66510.1179/174329306X147742 ↗
19. C. Chen and R. Kovacevic, 2004 Thermomechanical Modelling and Force Analysis of Friction Stir Welding by the Finite Element Method, Proc. IME C J. Mech. Eng. Sci., 218(5), 509–51910.1243/095440604323052292 ↗
20. R. Johnson, Forces in Friction Stir Welding of Aluminum Alloys, Presented at the 3rd International Symposium on Friction Stir Welding (Kobe, Japan), Sep 2001, p 6–19
21. J.W. Pew, “A Torque-Based Weld Power Model for Friction Stir Welding”, M.Sc. Thesis, Brigham Young University, 2006
22. D. Jandric, M. Chen, M. Valant, and R. Kovacevic, Characterization of Weld Quality by Different Sensing Techniques in Friction Stir Welding of Lap Joints, Presented at 4th International Symposium on Friction Stir Welding (Park City, Utah), May 2003, p 6
23. R.R. Itharaju, “Friction Stir Processing of Aluminum Alloys,” M.Sc. Thesis, University of Kentucky, 2004
24. Y.T. Chew, M. Cheng, and S·C. Luo, 1995 A Numerical Study of Flow Past a Rotating Circular Cylinder Using a Hybrid Vortex Scheme, J. Fluid Mech., 299, 35–7110.1017/S0022112095003417 ↗
25. S. Mittal, B. Kumar, 2003 Flow Past a Rotating Cylinder, J. Fluid Mech., 476, 303–33410.1017/S0022112002002938 ↗
26. O·C. Zienkiewicz, P·C. Jain, and E. Onate, 1978. Flow of Solids During Forming and Extrusion: Some Aspects of Numerical Solutions, Int. J. Solid Struct., 14, 15–3810.1016/0020-7683(78)90062-8 ↗
27. W.J. Arbegast, Modeling Friction Stir Joining as a Metalworking Process, Proceedings of Symposium on Hot Deformation of Aluminum Alloys III, March 2-6, 2003 (San Diego, California), TMS, p 313–327
28. N. Cristescu and I. Suliciu, Viscoplasticity (Mechanics of Plastic Solids). Kluwer Academic Publishers, Dordrecht, 1982
29. P. Dong, F. Lu, J.K. Hong, and Z. Cao, 2001. Coupled Thermomechanical Analysis of Friction Stir Welding Process Using Simplified Models, Sci. Technol. Welding Joining, 6(5), 281–28710.1179/136217101101538884 ↗
30. T. Sheppard and D.S. Wright, Determination of Flow Stress I-Constitutive Equation for Aluminum Alloys at Elevated Temperatures. II-Radial and Axial Temperature Distribution During Torsion Testing, Met. Tech., 1979, 6, 215–22910.1179/030716979803276264 ↗
31. T. Sheppard, A. Jackson, 1979 Constitutive Equations for Use in Prediction of Flow Stress During Extrusion of Aluminum Alloys, Mater. Sci. Tech., 13(3), 203–20910.1179/mst.1997.13.3.203 ↗
32. R.I. Tanner, Engineering Rheology, 2nd ed., Oxford University Press, May 200010.1093/oso/9780198564737.001.0001 ↗
33. W. Zhang, G.G. Roy, J. Elmer, and T. DebRoy, 2003 Modeling of Heat Transfer and Fluid Flow During Gas Tungsten Arc Spot Welding of Low Carbon Steel, J. Appl. Phys., 93(5), 3022–303310.1063/1.1540744 ↗
34. H·N.B. Schmidt, J. Hattel, 2004 Heat Sources Models in Simulation of Heat Flow in Friction Stir Welding, Int. J. Offshore Polar Eng., 14(4), 296–304
35. M. Song, R. Kovacevic, 2004 Heat Transfer Modelling for Both Workpiece and Tool in the Friction Stir Welding Process: A Coupled Model, Proc. IME. B J. Eng. Manufact., 218(1), 17–3310.1243/095440504772830174 ↗
36. H. Atharifar and R. Kovacevic, Computational Study on the Qualitative Effect of Process Parameters on the Forces and Torque Applied to the Tool in Friction Stir Welding, Presented at ASME GSRIC Conference (Tulsa, OK), April 2007
37. H. Atharifar and R. Kovacevic, Numerical Study of the Tool Rake Angle Affect on the Material Flow in Friction Stir Welding Process, Presented at ASME International Mechanical Engineering Congress and Exposition (Seattle, WA), Nov 200710.1115/IMECE2007-41962 ↗
38. L.F. Mondolfo 1976. Aluminum Alloys: Structure and Properties. Butterworth & Co., Boston, MA, pp 717–857