The Influence of Friction Stir Welding Process Idealization on Residual Stress and Distortion Predictions for Future Airframe Assembly Simulations

2012 ◽  
Vol 134 (3) ◽  
Author(s):  
R. W. McCune ◽  
A. Murphy ◽  
M. Price ◽  
J. Butterfield
Keyword(s):  
Residual Stress ◽  
Friction Stir Welding ◽  
Residual Stresses ◽  
Welding Process ◽  
Structural Components ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Computationally Expensive ◽  
Forging Force ◽  
Process Speed

The ability to accurately predict residual stresses and resultant distortions is a key product from process assembly simulations. Assembly processes necessarily consider large structural components potentially making simulations computationally expensive. The objective herein is to develop greater understanding of the influence of friction stir welding process idealization on the prediction of residual stress and distortion and thus determine the minimum required modeling fidelity for future airframe assembly simulations. The combined computational and experimental results highlight the importance of accurately representing the welding forging force and process speed. In addition, the results emphasize that increased CPU simulation times are associated with representing the tool torque, while there is potentially only local increase in prediction fidelity.

Comparison of Residual Stress Between MIG Welding and Friction Stir Welding

2012 ◽  
Vol 155-156 ◽  
pp. 1218-1222
Author(s):  
Lei Wang ◽  
Mitsuyosi Tsunori
Keyword(s):  
Residual Stress ◽  
Friction Stir Welding ◽  
Stress Distribution ◽  
Yield Strength ◽  
Room Temperature ◽  
Welding Process ◽  
Residual Stress Distribution ◽  
Mig Welding ◽  
Friction Stir ◽  
Friction Stir Welding Process

Residual stress distribution plays a very important role in welded structures, the aim of present work is to find out the effect of different welding methods on the residual stress distribution by means of neutron diffraction measurements and FE models simulation. 4 mm thick DH-36 steel plates were butt welded by MIG welding process and 5 mm thick AA 2024 aluminium alloy plates were butt welded by friction stir welding process. Results show that residual stresses of MIG welding process are higher than those of friction stir welding process. The peak residual stress of MIG weld is close to the room temperature uniaxial yield strength of DH-36 while the peak residual stress of friction stir weld is just about 50% of the room temperature uniaxial yield strength of AA2024. The size effect of MIG welded and effect of welding speeds of friction stir welded on the residual stress distribution have also been studied in the paper.

Study on the effect of the welding environment on the dynamic recrystallization phenomenon and residual stresses during the friction stir welding process of aluminum alloy

2021 ◽  
pp. 146442072110251
Author(s):  
Mahmoud Abbasi ◽  
Amin Abdollahzadeh ◽  
Behrouz Bagheri ◽  
Ahmad Ostovari Moghaddam ◽  
Farzaneh Sharifi ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Residual Stresses ◽  
Welding Process ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Underwater Friction Stir Welding ◽  
Processed Sample ◽  
Vibration Welding ◽  
Strength And Ductility

Various methods have been proposed to modify the friction stir welding. Friction stir vibration welding and underwater friction stir welding are two variants of this technique. In friction stir vibration welding, the adjoining workpieces are vibrated normal to the joint line while friction stir welding is carried out, while in underwater friction stir welding the friction stir welding process is performed underwater. The effects of these modified versions of friction stir welding on the microstructure and mechanical characteristics of AA6061-T6 aluminum alloy welded joints are analyzed and compared with the joints fabricated by conventional friction stir welding. The results indicate that grain size decreases from about 57 μm for friction stir welding to around 34 μm for friction stir vibration welding and about 23 μm for underwater friction stir welding. The results also confirm the evolution of Mg2Si precipitates during all processes. Friction stir vibration welding and underwater friction stir welding processes can effectively decrease the size and interparticle distance of precipitates. The strength and ductility of underwater friction stir welding and friction stir vibration welding processed samples are higher than those of the friction stir welding processed sample, and the highest strength and ductility are obtained for underwater friction stir welding processed samples. The underwater friction stir welding and friction stir vibration welding processed samples exhibit about 25% and 10% higher tensile strength compared to the friction stir welding processed sample, respectively. The results also indicate that higher compressive residual stresses are developed as underwater friction stir welding and friction stir vibration welding are applied.

Evaluation of 7050 Aluminum Plates Joined by Friction Stir Welding Using Acoustoelastic

2017 ◽  
Author(s):  
Shirley Alexandra García Ruano ◽  
Felipe Bertelli ◽  
Auteliano Antunes dos Santos
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Residual Stresses ◽  
Ultrasonic Method ◽  
Welding Process ◽  
Longitudinal Direction ◽  
Structural Components ◽  
Friction Stir ◽  
Low Weight ◽  
Aluminum Plates

The 7050-T7451 aluminum alloy has been widely used in the aerospace industry. Due to its chemical composition, this alloy has high levels of mechanical properties that allow the production of low-weight aircraft structural components. However, these alloys are thermally treatable and are not able to bear manufacturing processes involving heat. Because of the importance of their applications, studies based on the development of solid state welding process would be desirable aiming to find an alternative to generate welded joints for this kind of components. In this work, an investigation concerning the behavior of the 7050-T7451 aluminum alloy during Friction Stir Welding (FSW) was carried out. The profile of longitudinal residual stresses of plates welded by the FSW process was obtained using the ultrasonic method through critically refracted longitudinal waves (LCR). Two different frequencies were employed, 3.5 MHz and 5 MHz. The measurements were performed in the longitudinal direction of the welded joint at different distances from the center line of the weld. The magnitude and distribution of residual stresses found with this method are consistent with literature review, reaching 150MPa on the center of the weld.

Temperature distribution and residual stress in Friction Stir Welding process

2020 ◽  
Vol 26 ◽  
pp. 2296-2301 ◽  
Author(s):  
Smrity Choudhury ◽  
Tanmoy Medhi ◽  
Durjyodhan Sethi ◽  
Sanjeev Kumar ◽  
Barnik Saha Roy ◽  
...  
Keyword(s):  
Residual Stress ◽  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Welding Process ◽  
Friction Stir ◽  
Friction Stir Welding Process

Simulation of thermal behavior during friction stir welding process for predicting residual stresses

2014 ◽  
Vol 6 (2) ◽  
pp. 271-278
Author(s):  
Christian Dresbach ◽  
Marinus J. van Enkhuizen ◽  
Ulises Alfaro Mercado ◽  
Stefan Reh
Keyword(s):  
Friction Stir Welding ◽  
Residual Stresses ◽  
Thermal Behavior ◽  
Welding Process ◽  
Friction Stir ◽  
Friction Stir Welding Process

Influence of the clamps configuration on residual stresses field in friction stir welding process

2015 ◽  
Vol 50 (4) ◽  
pp. 232-242 ◽  
Author(s):  
Caterina Casavola ◽  
Alberto Cazzato ◽  
Vincenzo Moramarco ◽  
Carmine Pappalettere
Keyword(s):  
Friction Stir Welding ◽  
Residual Stresses ◽  
Welding Process ◽  
Friction Stir ◽  
Friction Stir Welding Process
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