A coupled experimental and numerical analysis of AA6063 friction stir welding

Abstract

In the present research, a coupled Eulerian–Lagrangian model is developed to predict the forces and defects produced from AA6063 friction stir welding process. Furthermore, the obtained results from the developed model were validated experimentally by performing the welding process at different rotational and welding speed values. The results revealed an appearance of tunnel defect at all welded joints with surface flash. The current model successfully predicted both defects’ evolution. Additionally, it also generated force measurements comparable to those obtained experimentally. In addition, the developed Coupled Eulerian–Lagrangian model successfully predicted the generated force and the defects during friction stir welding process with maximum error of 14% and 18%. However, it failed in predicting the tunnel positions. In terms of the tensile strength, the largest tensile strength value was at 1250rpm and 50 mm/min, whereas the lowest one was at 1000 rpm and 25 mm/min. Moreover, the fracture locations were at the advancing side of all the welded joints.

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

“…Mass scaling enables the discretization of the solution domain into multiple small elements [235]. However, applying mass scaling automatically may not always be feasible, leading researchers to explore a manual approach of multiplying the density with a mass scaling factor, as discussed in the literature [236].…”

Effect of Friction Stir Welding on Microstructure and Mechanical Properties of uns C19400 Alloy Plates

“…Another advantage of the process is to produce joints of similar and dissimilar materials that would be difficult to weld using conventional methods, generating less distortion due to the low heat input offered compared to traditional methods 2 . The aerospace, automobile, naval and energy industries are the main researchers and developers of the FSW technique [3][4][5][6][7] .…”