A Comparative Study of Material Flow Behavior in Friction Stir Welding Using Laminar and Turbulent Models
Source abstract
Abstract
Friction stir welding has been quite successful in joining aluminum alloy which has gained importance in almost all industrial sectors over the past two decades. It is a newer technique and therefore needs more attention in many sectors, flow of material being one among them. The material flow pattern actually helps in deciding the parameters required for particular tool geometry. The knowledge of material flow is very significant in removing defects from the weldment. In the work presented in this paper, the flow behavior of AA6061 under a threaded tool has been studied. The convective heat loss has been considered from all the surfaces, and a comparative study has been made with and without the use of temperature-dependent properties and their significance in the finite volume method model. The two types of models that have been implemented are turbulent and laminar models. Their thermal histories have been studied for all the cases. The material flow velocity has been analyzed to predict the flow of material. A swirl inside the weld material has been observed in all the simulations.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Advanced Welding Techniques Analysis · Metal Forming Simulation Techniques · Aluminum Alloys Composites Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (28)
Show source-provided references
1. W.M. Thomas, E. N.-S, Patent No. 9,125,978.8, 199110.1300/J120v14n32_09 ↗
2. E. Nicholas, Developments in the Friction-Stir Welding of Metals, ICAA-6, 6th International Conf. on Aluminium Alloys. Toyohashi, Japan, 1998
3. R.U. Kailas, Numerical Analysis of Friction Stir Welding Process, J. Mater. Eng. Perform., 2013, 22, p 2921–293410.1007/s11665-013-0729-2 ↗
4. E. Feulvarch, J.C. Roux, and J.M. Bergheau, A Simple and Robust Moving Mesh Technique for the Finite Element Simulation of Friction Stir Welding, J. Comput. Appl. Math., 2012, 246, p 269–27710.1016/j.cam.2012.07.013 ↗
5. H.W. Zhang, Z. Zhang, and J.T. Chen, 3D Modeling of Material Flow in Friction Stir Welding Under Different Process Parameters, J. Mater. Process. Technol., 2007, 183, p 62–7010.1016/j.jmatprotec.2006.09.027 ↗
6. W.L. Zhihan Zhang, Numerical Analysis of Effect of Backplate Diffusivity on the Transient Temperature in Friction Stir Welding, J. Mater. Eng. Perform., 2013, 22, p 2446–245010.1007/s11665-013-0538-7 ↗
7. S.X. Xiaomin Deng, Two-Dimensional Finite Element Simulation of Material Flow in the Friction Stir Welding Process, J. Manuf. Process., 2004, 6, p 2
8. W.U. Chuan-song and W. Zhang, Visualization and Simulation of Plastic Material Flow in Friction Stir Welding of 2024 Aluminium Alloy Plates, Trans. Nonferrous Met. Soc. China, 2012, 22, p 1445–145110.1016/S1003-6326(11)61339-3 ↗
9. H. Jamshidi Aval and S. Serajzadeh, Evolution of Microstructures and Mechanical Properties in Similar and Dissimilar Friction Stir Welding of AA5086 and AA6061, Mater. Sci. Eng. A, 2011, 528, p 8071–808310.1016/j.msea.2011.07.056 ↗
10. V.F. Olivier Lorrain, Understanding the Material Flow Path of Friction Stir Welding Process Using Unthreaded Tools, J. Mater. Process. Technol., 2010, 210, p 603–60910.1016/j.jmatprotec.2009.11.005 ↗
11. F. Simões and D. Rodrigues, Material Flow and Thermo-Mechanical Conditions During Friction Stir Welding of Polymers: Literature Review, Experimental Results and Empirical Analysis, Mater. Des., 2014, 59, p 344–35110.1016/j.matdes.2013.12.038 ↗
12. S.D. Ji and Q. Shi, Numerical Simulation of Material Flow Behavior of Friction Stir Welding Influenced by Rotational Tool Geometry, Comput. Mater. Sci., 2012, 63, p 218–22610.1016/j.commatsci.2012.06.001 ↗
13. T.I. Yoshiaki Morisada, Three-Dimensional Visualization of Material Flow During Three-Dimensional Visualization of Material Flow During, J. Mater. Eng. Perform., 2014, 23, p 4143–414710.1007/s11665-014-1202-6 ↗
14. M. Song and R. Kovacevic, Thermal Modeling of Friction Stir Welding in a Moving Coordinate System and its Validation, Int. J. Mach. Tools Manuf., 2003, 43, p 605–61510.1016/S0890-6955(03)00022-1 ↗
15. C.M. Chen and R. Kovacevic, Finite Element Modeling of Friction Stir Welding—Thermal and Thermomechanical Analysis, Int. J. Mach. Tools Manuf., 2003, 43, p 1319–132610.1016/S0890-6955(03)00158-5 ↗
16. D. Trimble and J. Monaghan, Force Generation During Friction Stir Welding of AA2024-T3, CIRP Ann. Manuf. Technol., 2012, 61, p 9–1210.1016/j.cirp.2012.03.024 ↗
17. G. Buffa, A. Ducato, and L. Fratini, Numerical Procedure for Residual Stresses Prediction in Friction Stir Welding, Finite Elem. Anal. Des., 2011, 47, p 470–47610.1016/j.finel.2010.12.018 ↗
18. D. Jacquin, B. De Meester, A. Simar, D. Deloison, F. Montheillet, and C. Desrayaud, A Simple Eulerian Thermomechanical Modeling of Friction Stir Welding, J. Mater. Process. Technol., 2011, 211, p 57–6510.1016/j.jmatprotec.2010.08.016 ↗
19. P. Heurtier and M.J. Jones, Mechanical and Thermal Modeling of Friction Stir Welding, J. Mater. Process. Technol., 2006, 172, p 152–15810.1016/j.jmatprotec.2005.09.015 ↗
20. H.B. Dongun Kim, Numerical Simulation of Friction Stir Butt Welding Process for AA5083-H18 Sheets, Eur. J. Mech. A, 2010, 29, p 204–21510.1016/j.euromechsol.2009.10.006 ↗
21. S.D. Carter Hamiltona, A Model of Material Flow During Friction Stir Welding, Mater. Charact., 2008, 59, p 1206–121410.1016/j.matchar.2007.10.002 ↗
22. K. Kumar and S.V. Kailas, The role of Friction Stir Welding Tool on Material flow and Weld Formation, Mater. Sci. Eng. A, 2008, 485, p 367–37410.1016/j.msea.2007.08.013 ↗
23. H.J. Zhang and H. Liu, Effect of Water Cooling on the Performances of Friction Stir Welding Heat-Affected Zone, J. Mater. Eng. Perform., 2012, 21, p 1182–118710.1007/s11665-011-0060-8 ↗
24. A. Astarita and A. Squillace, Experimental Study of the Forces Acting on the Tool in the Friction-Stir Welding of AA 2024 T3 Sheets, J. Mater. Eng. Perform., 2014, 23, p 3754–376110.1007/s11665-014-1140-3 ↗
25. M.R. Nazari, Analysis of Transient Temperature and Residual Thermal Stresses in Friction Stir Welding of Aluminum Alloy 6061-T6 via Numerical Simulation, Int. J. Adv. Manuf. Technol., 2011, 55, p 143–15210.1007/s00170-010-3038-z ↗
26. A.T. Quested, The Viscosity of Aluminium and its Alloys—A Review of Data and Models, J. Mater. Sci., 2004, 39, p 7221–722810.1023/B:JMSC.0000048735.50256.96 ↗
27. A.P. Colegrove and R.S. Hugh, 3-Dimensional CFD Modelling of Flow Round a Threaded Friction Stir Welding Tool Profile, J. Mater. Process. Technol., 2005, 169, p 320–32710.1016/j.jmatprotec.2005.03.015 ↗
28. K.E. Tello and A.P. Gerlich, Constants for Hot Deformation Constitutive Models for Recent Experimental Data, Sci. Technol. Weld. Join., 2010, 15, p 260–26610.1179/136217110X12665778348380 ↗