A review of numerical analysis of friction stir welding

He, Xiaocong; Gu, Fengshou; Ball, Andrew

doi:10.1016/j.pmatsci.2014.03.003

Cited by 414 publications

(178 citation statements)

References 328 publications

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“…In 1991, a new solid state process was patented by The Welding Institute in United Kingdom, and this is Friction Stir Welding (FSW) [24], which is commonly used for materials that are difficult to join by fusion-based processes [25]. In FSW a non-consumable rotating tool consisting of a pin and a shoulder provides mechanical mixing and viscoplastic deformation of the materials in the area to weld.…”

Section: Progress In Materials Science XXX (2017) Xxx-xxxmentioning

confidence: 99%

“…Friction welding has several variants which are dependent on the processes and equipment involved: linear friction welding [60]; rotary friction welding [61]; spin welding [62]; inertia friction welding [63]; and friction stir welding [25]. From these, friction stir welding is the most recent and, as such, special attention has been devoted to this technique.…”

Section: Friction Weldingmentioning

confidence: 99%

See 1 more Smart Citation

Welding and Joining of NiTi Shape Memory Alloys: A Review

Oliveira

Miranda

Fernandes

2017

Progress in Materials Science

268

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Section: Progress In Materials Science XXX (2017) Xxx-xxxmentioning

confidence: 99%

Section: Friction Weldingmentioning

confidence: 99%

Welding and Joining of NiTi Shape Memory Alloys: A Review

Oliveira

Miranda

Fernandes

2017

Progress in Materials Science

268

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“…Developments of microstructures and the properties of material during the FSW was done by He et al [44]. The results from the research indicated that, the material properties, the tool geometry and the joint shape affect the welding quality.…”

Section: Thermal Analysis Of Fsw (Friction Stir Welding)mentioning

confidence: 99%

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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Friction Stir Welding (FSW) is a novel kind of welding for joining metals that are impossible or difficult to weld by conventional methods. Three-dimensional nature of FSW makes the experimental investigation more complex. Moreover, experimental observations are often costly and time consuming, and usually there is an inaccuracy in measuring the data during experimental tests. Thus, Finite Element Methods (FEMs) has been employed to overcome the complexity, to increase the accuracy and also to reduce costs. It should be noted that, due to the presence of large deformations of the material during FSW, strong distortions of mesh might be happened in the numerical simulation. Therefore, one of the most significant considerations during the process simulation is the selection of the best numerical approach. It must be mentioned that; the numerical approach selection determines the relationship between the finite grid (mesh) and deforming continuum of computing zones. Also, numerical approach determines the ability of the model to overcome large distortions of mesh and provides an accurate resolution of boundaries and interfaces. There are different descriptions for the algorithms of continuum mechanics include Lagrangian and Eulerian. Moreover, by combining the above-mentioned methods, an Arbitrary Lagrangian-Eulerian (ALE) approach is proposed. In this paper, a comparison between different numerical approaches for thermal analysis of FSW at both local and global scales is reviewed and the applications of each method in the FSW process is discussed in detail. Observations showed that, Lagrangian method is usually used for modelling thermal behavior in the whole structure area, while Eulerian approach is seldom employed for modelling of the thermal behavior, and it is usually employed for modelling the material flow. Additionally, for modelling of the heat affected zone, ALE approach is found to be as an appropriate approach. Finally, several significant challenges and subjects remain to be addressed about FSW thermal analysis and opportunities for the future work are proposed.

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“…There have been several studies in the literature reporting on modelling of FSW [7][8][9][10][11] concentrated in simulation of the process and limit capacity analysis. Modelling for these types of analysis required detailed mesh in order to work out a smooth stress field within and around FSW weld joint.…”

Section: Introductionmentioning

confidence: 99%

Finite element modelling and updating of friction stir welding (FSW) joint for vibration analysis

2016

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Abstract.Friction stir welding of aluminium alloys widely used in automotive and aerospace application due to its advanced and lightweight properties. The behaviour of FSW joints plays a significant role in the dynamic characteristic of the structure due to its complexities and uncertainties therefore the representation of an accurate finite element model of these joints become a research issue. In this paper, various finite elements (FE) modelling technique for prediction of dynamic properties of sheet metal jointed by friction stir welding will be presented. Firstly, nine set of flat plate with different series of aluminium alloy; AA7075 and AA6061 joined by FSW are used. Nine set of specimen was fabricated using various types of welding parameters. In order to find the most optimum set of FSW plate, the finite element model using equivalence technique was developed and the model validated using experimental modal analysis (EMA) on nine set of specimen and finite element analysis (FEA). Three types of modelling were engaged in this study; rigid body element Type 2 (RBE2), bar element (CBAR) and spot weld element connector (CWELD). CBAR element was chosen to represent weld model for FSW joints due to its accurate prediction of mode shapes and contains an updating parameter for weld modelling compare to other weld modelling. Model updating was performed to improve correlation between EMA and FEA and before proceeds to updating, sensitivity analysis was done to select the most sensitive updating parameter. After perform model updating, total error of the natural frequencies for CBAR model is improved significantly. Therefore, CBAR element was selected as the most reliable element in FE to represent FSW weld joint.

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A review of numerical analysis of friction stir welding

Cited by 414 publications

References 328 publications

Welding and Joining of NiTi Shape Memory Alloys: A Review

Welding and Joining of NiTi Shape Memory Alloys: A Review

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Finite element modelling and updating of friction stir welding (FSW) joint for vibration analysis

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