An analytical model to optimize rotation speed and travel speed of friction stir welding for defect-free joints

Temperature measurements during friction stir welding

“…As the industrial demand for lightweight products with increased geometrical complexity rises, there is a need for better process control, in order to guarantee a consistent weld quality. Furthermore, feedback of process variables during welding allows a systematic approach for weld parameter window development, instead of the trial-and-error approach which is often adopted [4].…”

“…The weld parameters, material thickness, the alloy to be welded and the tool design strongly affect the weld temperature [2,3,5], and the backing bar material has also been reported to have an influence [5,6]. The implementation of temperature control for FSW allows optimisation of the process and is in some applications essential to obtain sound welds [2][3][4][5]7]. A welding parameter's window based on "hot" and "cold" weld boundaries is usually adopted to achieve sound welds.…”

“…In this case, a self-limiting system is achieved, where the material at the tool-workpiece interface transfers from a stick-to-slip phase as the T S is reached, decreasing the heat generation due to the reduction on friction [2,3,10]. The weld temperature to achieve sound welds has been reported just below the T S measured in centigrade, in the range of 80 % T S [6], 60-90 % T S [2] or 80-90 % T S [4].…”

Verification of Johnson-Cook Material Model Constants of Aa2024-T3 for Use in Finite Element Simulation of Friction Stir Welding and Its Utilization in Severe Plastic Deformation Process Modelling

“…The simulations were performed for the values shown in Table-2 Here, for all the cases considered the melting temperature of material and room temperature are 502°C and 25°C respectively. From the literature it is found that, working temperatures in FSW should be around 0.8-0.9 T melt [23] for obtaining defect free welds with any set of parameters used in welding. The temperature range from literature, macrographs obtained from experiment and temperature readings measured during experiment using thermocouples are considered in studying the effect of Johnson-Cook material constants at different cases.…”

Optimization of Friction Stir Weld Joint Quality Using a Meshfree Fully-Coupled Thermo-Mechanics Approach

“…The area is calculated from A so = 2(L wz W wz ) + 2(h wz W wz ) + π r pin 2 l pin + r pin (11) which includes an approximation for the surface area associated with the hole created by the pin of length l pin and radius r pin . The material points that belong to the free surface are determined via…”