Top

The International Journal of Advanced Manufacturing Technology

Published in:

04-01-2020 | ORIGINAL ARTICLE

Prediction of temperature and residual stress distributions in friction stir welding of aluminum alloy

Authors: L. Nie, Y. X. Wu, H. Gong

Published in: The International Journal of Advanced Manufacturing Technology | Issue 7-8/2020

Activate our intelligent search to find suitable subject content or patents.

search-config

AI-assisted search

Off

Abstract

A thermal model considering the heat generated by friction and plastic deformation is developed for friction stir welding. The proportion of heat-generated between friction and plastic deformation depends on the contact states determined by the temperature and velocity of the tool. The model is verified by welding experiment, and the numerical results agree with the experimental data. Then, the effects of process parameters on temperature and residual stress are investigated using the validated model. These process parameters involve the welding speed, rotational speed, and axial force. The results show that the temperature increases with the increase of the rotational speed and axial force, and decreases with the increase of the welding speed. The increase of the axial force and welding speed will lead to larger tensile stress in the weld zone. Furthermore, the relationship between peak temperature, peak residual stress, and process parameters are established though regression method.

previous article An investigation on the effect of different coated electrodes on the surface quality of WEDM by varying discharge energy level

next article Investigation on the formation mechanism and controlling method of machined surface topography of ultra-precision flycutting machining

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

inform now

Dialami N, Chiumenti M, Cervera M, Saracibar CAD (2017) Challenges in thermo-mechanical analysis of friction stir welding processes. Arch Comput Method Eng 24(1):189–225. https://doi.org/10.1007/s11831-015-9163-y CrossRefMATH

He X, Gu F, Ball A (2014) A review of numerical analysis of friction stir welding. Prog Mater Sci 65(10):1–66. https://doi.org/10.1016/j.pmatsci.2014.03.003 CrossRef

Sun T, Roy MJ, Strong D, Simpson C, Withers PJ, Prangnell PB (2019) Weld zone and residual stress development in AA7050 stationary shoulder friction stir T-joint weld. J Mater Process Technol 263:256–265. https://doi.org/10.1016/j.jmatprotec.2018.08.022 CrossRef

Malard B, Geuser FD, Deschamps A (2015) Microstructure distribution in an AA2050 T34 friction stir weld and its evolution during post-welding heat treatment. Acta Mater 101:90–100. https://doi.org/10.1016/j.actamat.2015.08.068 CrossRef

Du Y, Li H, Yang L, Luo C (2018) Accurate measurement of residual stresses of 2219-T87 aluminum alloy friction stir welding joints based on properties of joints. J Mech Sci Technol 32(1):139–147. https://doi.org/10.1007/s12206-017-1215-9 CrossRef

Charitidis CA, Dragatogiannis DA, Koumoulos EP, Kartsonakis IA (2012) Residual stress and deformation mechanism of friction stir welded aluminum alloys by nanoindentation. Mater Sci Eng A 540:226–234. https://doi.org/10.1016/j.msea.2012.01.129 CrossRef

Sun Z, Wu CS, Kumar S (2018) Determination of heat generation by correlating the interfacial friction stress with temperature in friction stir welding. J Manuf Process 31:801–811. https://doi.org/10.1016/j.jmapro.2018.01.010 CrossRef

Sun T, Reynolds AP, Roy MJ, Withers PJ, Prangnell PB (2018) The effect of shoulder coupling on the residual stress and hardness distribution in AA7050 friction stir butt welds. Mater Sci Eng A 735:218–227. https://doi.org/10.1007/s00170-018-1857-5 CrossRef

Salari E, Jahazi M, Khodabandeh A, Ghasemi-Nanesa H (2014) Influence of tool geometry and rotational speed on mechanical properties and defect formation in friction stir lap welded 5456 aluminum alloy sheets. Mater Des 58:381–389. https://doi.org/10.1016/j.matdes.2014.02.005 CrossRef

10.

Rasti J (2018) Study of the welding parameters effect on the tunnel void area during friction stir welding of 1060 aluminum alloy. Int J Adv Manuf Technol 97(5–8):2221–2230. https://doi.org/10.1007/s00170-018-1857-5 CrossRef

11.

Paulo RMF, Carlone P, Paradiso V, Valente RAF, Teixeira-Dias F (2017) Prediction of friction stir welding effects on AA2024-T3 plates and stiffened panels using a shell-based finite element model. Thin Wall Struct 120:297–306. https://doi.org/10.1016/j.tws.2017.09.009 CrossRef

12.

Su H, Wu CS, Pittner A, Rethmeier M (2014) Thermal energy generation and distribution in friction stir welding of aluminum alloys. Energy 77:720–731. https://doi.org/10.1016/j.energy.2014.09.045 CrossRef

13.

Ghetiya ND, Patel KM (2018) Numerical simulation on an effect of backing plates on joint temperature and weld quality in air and immersed FSW of AA2014-T6. Int J Adv Manuf Technol 99(5–8):1937–1951. https://doi.org/10.1007/S00170-018-2632-3 CrossRef

14.

Zhang Z, Zhang HW (2014) Solid mechanics-based Eulerian model of friction stir welding. Int J Adv Manuf Technol 72(9–12):1647–1653. https://doi.org/10.1007/s00170-014-5789-4 CrossRef

15.

Wen Q, Li WY, Gao YJ, Yang J, Wang FF (2019) Numerical simulation and experimental investigation of band patterns in bobbin tool friction stir welding of aluminum alloy. Int J Adv Manuf Technol 100(9–12):2679–2687. https://doi.org/10.1007/s00170-018-2750-y CrossRef

16.

Yu H, Zheng B, Lai X (2018) A modeling study of welding stress induced by friction stir welding. J Mater Process Technol 254:213–220. https://doi.org/10.1016/j.jmatprotec.2017.11.022 CrossRef

17.

Bachmann M, Carstensen J, Bergmann L, Santos JFD, Wu CS, Rethmeier M (2017) Numerical simulation of thermally induced residual stresses in friction stir welding of aluminum alloy 2024-T3 at different welding speeds. Int J Adv Manuf Technol 91:1443–1452. https://doi.org/10.1007/s00170-016-9793-8 CrossRef

18.

Darvazi AR, Iranmanesh M (2014) Prediction of asymmetric transient temperature and longitudinal residual stress in friction stir welding of 304L stainless steel. Mater Des 55:812–820. https://doi.org/10.1016/j.matdes.2013.10.030 CrossRef

19.

Yan DY, Wu AP, Silvanus J, Shi QY (2011) Predicting residual distortion of aluminum alloy stiffened sheet after friction stir welding by numerical simulation. Mater Des 32(4):2284–2291. https://doi.org/10.1016/j.matdes.2010.11.032 CrossRef

20.

Wan ZY, Zhang Z, Zhou X (2017) Finite element modeling of grain growth by point tracking method in friction stir welding of AA6082-T6. Int J Adv Manuf Technol 90(9–12):3567–3574. https://doi.org/10.1007/s00170-016-9632-y CrossRef

21.

Schmidt H, Hattel J, Wert J (2004) An analytical model for the heat generation in friction stir welding. Model Simul Mater Sc 12(1):143–157. https://doi.org/10.1088/0965-0393/12/1/013 CrossRef

22.

Su H, Wu CS, Bachmann M, Rethmeier M (2015) Numerical modeling for the effect of pin profiles on thermal and material flow characteristics in friction stir welding. Mater Des 77:114–125. https://doi.org/10.1016/j.matdes.2015.04.012 CrossRef

23.

Gerlich A, Yamamoto M, North TH (2007) Strain rates and grain growth in Al 5754 and Al 6061 friction stir spot welds. Metall Mater Trans A 38(6):1291–1302. https://doi.org/10.1007/s11661-007-9155-0 CrossRef

24.

Qian JW, Li JL, Xiong JT, Zhang FS, Li WY, Lin X (2012) Periodic variation of torque and its relations to interfacial sticking and slipping during friction stir welding. S Sci Technol Weld Join 17(4):338–341. https://doi.org/10.1179/1362171812Y.0000000001 CrossRef

25.

Zhang XX, Xiao BL, Ma ZY (2011) A transient thermal model for friction stir weld. Part I: the model. Metall Mater Trans A 42(10):3218–3228. https://doi.org/10.1007/s11661-011-0729-5 CrossRef

26.

Frigaard Ø, Grong Ø, Midling OT (2001) A process model for friction stir welding of age hardening aluminum alloys. Metall Mater Trans A 32(5):1189–1200. https://doi.org/10.1007/s11661-001-0128-4 CrossRef

27.

Cho HH, Hong ST, Roh JH, Choi HS, Kang SH, Steel RJ, Han HN (2013) Three-dimensional numerical and experimental investigation on friction stir welding processes of ferritic stainless steel. Acta Mater 61(7):2649–2661. https://doi.org/10.1016/j.actamat.2013.01.045 CrossRef

28.

ASM Handbook Committee (1990) ASM Handbook Vol. 2: Properties and selection: nonferrous alloys and special-purpose materials. ASM International, Ohio, pp 62–122

29.

Kaufman JG (1999) Properties of aluminum alloys: tensile, creep, and fatigue data at high and low temperatures. ASM international, Washington

30.

Meng QG, Fang HY, Yang JG, Ji SD (2005) Analysis of temperature and stress field in Al alloy’s twin wire welding. Theor Appl Fract Mec 44(2):178–186. https://doi.org/10.1016/j.tafmec.2005.06.006 CrossRef

31.

Narender K, Rao ASM, Rao KGK, Krishna NG (2013) Thermo physical properties of wrought aluminum alloys 6061, 2219 and 2014 by gamma ray attenuation method. Thermochim Acta 569:90–96. https://doi.org/10.1016/j.tca.2013.07.003 CrossRef

Title: Prediction of temperature and residual stress distributions in friction stir welding of aluminum alloy
Authors: L. Nie
Y. X. Wu
H. Gong
Publication date: 04-01-2020
Publisher: Springer London
Published in: The International Journal of Advanced Manufacturing Technology / Issue 7-8/2020
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI: https://doi.org/10.1007/s00170-019-04826-4

Springer Professional

Abstract

Please log in to get access to your license.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Other articles of this Issue 7-8/2020

Experimental investigations on magnetic abrasive finishing of Ti-6Al-4V using a multiple pole-tip finishing tool

Fabrication and characterization of plastics with electrical and magnetic properties

Force-based reliability estimation of remaining cutting tool life in titanium milling

Analyses of two manufacturing systems in drilling of CGI: drilling and reaming × drilling

Two-step method to improve geometry accuracy of elongated hole flanging by electromagnetic forming

Milling process simulation for the variable pitch cutter based on an integrated process-machine model

Premium Partners