Transient model of heat transfer and material flow at different stages of friction stir welding process

2017 ◽  
Vol 25 ◽  
pp. 323-339 ◽  
Author(s):  
L. Shi ◽  
C.S. Wu
Keyword(s):  
Heat Transfer ◽  
Friction Stir Welding ◽  
Material Flow ◽  
Welding Process ◽  
Transient Model ◽  
Friction Stir ◽  
Friction Stir Welding Process

Finite Element Modelling of Temperature Distribution in Friction Stir Welding Process and Its Influence on Distortion of Copper Canisters

2004 ◽  
Vol 824 ◽  
Author(s):  
Therese Källgren ◽  
Lai-Zhe Jin ◽  
Rolf Sandström
Keyword(s):  
Finite Element ◽  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Welding Speed ◽  
Material Flow ◽  
Finite Element Modelling ◽  
Welding Process ◽  
Element Modelling ◽  
Friction Stir ◽  
Friction Stir Welding Process

AbstractIn an effort to enhance safety for long time disposal of waste nuclear fuel, friction stir welding has been developed as one alternative to seal copper canisters. To avoid the formation of voids and cracks during the welding process, an understanding of the heat and material flow andthereby the evolution of the microstructure, is of great importance. Finite element modelling has been used to simulate the heat and material flow as well as thermal expansion during the friction stir welding process. A model involving heat transfer, material flow, and continuum mechanics has been developed. The steady state solutions have been compared with experimental temperature observations as well as analytical solutions, showing good agreement. Temperature distribution is affected by the welding speed. For a given reference pointperpendicular to the welding direction, a lower welding speed corresponds to a higher peak temperature. The plunging position of welding tool influences the temperature distribution and therefore the displacement distribution of the weldment.

Numerical Analysis of In-Process Heat Transfer and Material Flow During Dissimilar Friction Stir Welding Process

2019 ◽  
Author(s):  
Gaoqiang Chen ◽  
Xun Liu ◽  
Qingyu Shi
Keyword(s):  
Heat Transfer ◽  
Friction Stir Welding ◽  
Material Flow ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Coupling Behavior ◽  
Dissimilar Friction Stir Welding ◽  
Computational Fluid Dynamics Cfd ◽  
Process Heat

Abstract Friction stir welding (FSW) has been successfully applied to join dissimilar materials in engineering applications. Fundamental understanding on the underlying physical principles of the dissimilar FSW process is generally required to achieve strong and reliable joints. In this study, we aim to develop a theoretical and numerical model based on computational fluid dynamics (CFD) in order to analyze the in-process heat transfer and material flow during the dissimilar FSW of aluminum and steel. The model describes the coupling behavior between the material distribution, thermal-mechanical properties, interfacial friction, heat generation and transfer. To account for the different material behaviors in stirring zone, a VOF-based approach is adopted. In this paper, preliminary numerical simulation is conducted. Simulation results show that the current modeling approach has the capability to capture the material mixing during the dissimilar FSW of aluminum and steel. The predicted temperature field is shown to be asymmetrical, which is attributed to the different properties of aluminum and steel. The predicted thermal history agrees with the experimental measurements in the literature.

An analytical and experimental investigation considering the effect of material flow velocity on tensile strength of a steel alloy joint produced by friction stir welding process

2020 ◽  
pp. 095440622093631
Author(s):  
Behzad Hadi ◽  
ME Aalami-Aleagha ◽  
Saeed Feli
Keyword(s):  
Friction Stir Welding ◽  
Flow Velocity ◽  
Analytical Method ◽  
Rotational Speed ◽  
Material Flow ◽  
Welding Process ◽  
Linear Speed ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Tool Pin

In this paper, the effects of linear speed, rotational speed, and tool radius of the pin and shoulder are investigated on the material flow velocity in friction stir welds. To obtain the maximum material flow velocity by an analytical method, a suggested relation is introduced for the rotational speed and tool optimum radius. The derived relation is based on the assumption of a velocity field in the stirring region. Besides, the effect of the linear speed on material flow velocity is investigated based on continuity and momentum equations. Finally, by using the experimental method and checking the mechanical properties of the welded parts obtained with different rotational speed, linear speed, and tool dimensions, the proposed analytical model is validated. The results indicate that in the friction stir welding process, the significant component effect on the stirring process is generated through the tool pin radius size. Besides, increasing the material flow velocity in the boundary layer increases the yield and ultimate strength of welds. To achieve the high-quality welds, rotational speed and other tool dimensions must be selected considering the equation extracted from the analytical method. Also, to make the maximum life for the pin and its components in friction stir welding of high melting point metals such as steel alloys, the operation is adjusted at a lower linear speed to prevent the destruction of the tool and improve the quality of the joint.

scholarly journals Modeling and Simulation Based Analysis of the Matter Flow During Friction Stir Welding Process

2021 ◽  
Vol 54 (2) ◽  
pp. 363-369
Author(s):  
Zine El Abidine Harchouche ◽  
Abdelkader Lousdad ◽  
Mothtar Zemri ◽  
Nabila Dellal ◽  
Foudil Khelil
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Rapid Development ◽  
Thermal Power ◽  
Great Part ◽  
Welding Process ◽  
Industrial Applications ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Tool Pin

Friction Stir Welding (FSW) is a recent assembly process which has been developed at the British Welding Institute (TWI) at the beginning of the 90's. This welding process has gone a rapid development and an increasing success. Many remarkable industrial applications achieved mainly in spatial, aeronautical, automobile, railways, marine and naval industries.... The translation and the rotation of the tool during the FSW process generate the flow and plastic deformation of the material which had been often differently interpreted in contradictory manner. In this paper, an analytical model is proposed to describe the flow of matter in the vicinity of the FSW tool pin during the welding process. Analytical solutions are elaborated on the basis of conventional fluid mechanics theory which is used to solve the associated equation to the mentioned problem based on the Laurent's series (called also Laurent's development). The knowledge of the material flow around the tool pin can lead to a better understanding of the metallurgical phenomena which have a significant effect on the mechanical properties of the welded joint and allows a better description of the speed fields which is worth full for the thermal modelisation since the great part of the thermal power is generated by auto-heating energy. The results obtained on the effect of the speeds on the material flow are in good accordance with the experimental results found in the literature. The study highlights and gives a better understanding of the material flow phenomenon during the Friction Stir Welding process.

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