CFD modelling of ultra-high rotational speed micro friction stir welding

Mohan, Renju; Jayadeep, U. B.; Manu, R.

doi:10.1016/j.jmapro.2021.02.060

Cited by 16 publications

(8 citation statements)

References 24 publications

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“…405 There are several types of welding processes, such as laser beam welding (LBW), electron beam welding (EBW), active-tungsten inert gas (TIG), 406 alternative current (AC) flash welding, 407 and microfriction stir welding (μFSW). 408 Figure 19 (a) shows the LBW processes as representatives. During welding, the power from the heat source will cause localized bulk materials to melt to form a weld pool, as shown in Figure 19 (b),(c).…”

Section: Phase Change For Other Purposesmentioning

confidence: 99%

“…Assembling two workpieces by welding is one of the critical technologies for reactors, aircraft, and automobiles . There are several types of welding processes, such as laser beam welding (LBW), electron beam welding (EBW), active-tungsten inert gas (TIG), alternative current (AC) flash welding, and microfriction stir welding (μFSW) Figure (a) shows the LBW processes as representatives.…”

Section: Phase Change For Other Purposesmentioning

confidence: 99%

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Recent Advances in CFD Simulations of Multiphase Flow Processes with Phase Change

Zhu

Zhang

et al. 2023

Ind. Eng. Chem. Res.

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Phase change is a phenomenon that has been extensively utilized in chemical engineering, energy, electronics, vehicle, and space exploration. From both the science and engineering perspectives, gaining a profound understanding of the intricacies of multiphase flow processes accompanied by heat and mass transfer due to phase change is of fundamental importance. Indeed, the computational fluid dynamics (CFD) has been increasingly applied as an effective tool to give an in-depth and efficient analysis of the phase change processes, thereby enhancing our understanding and capacity to control and optimize the phase change effects in these processes. This paper seeks to provide a comprehensive review of the utilization of CFD methodologies in the simulations of phase change flows across various applications, including temperature management, drying, separation and purification, and others. First, the CFD models at various scales that are developed to elucidate the phase change processes are summarized. Second, the noteworthy advances in the recent CFD simulation work on various phase change processes are presented, respectively. Finally, the challenges and potential prospects to facilitate the application of the phase change flow are discussed. The current review aims to offer insightful guidance for the CFD modeling of phase change processes in numerous engineering application scenarios.

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Section: Phase Change For Other Purposesmentioning

confidence: 99%

Section: Phase Change For Other Purposesmentioning

confidence: 99%

Recent Advances in CFD Simulations of Multiphase Flow Processes with Phase Change

Zhu

Zhang

et al. 2023

Ind. Eng. Chem. Res.

View full text Add to dashboard Cite

show abstract

“…Two primary thermomechanical modeling techniques are used for numerical simulation: 1. Computational fluid dynamics (CFD) models [14,[39][40][41][42][43][44][45][46][47][48]; 2. Computational solid mechanics (CSM) models.…”

Section: Process Modeling Techniquesmentioning

confidence: 99%

A Review on Friction Stir Welding/Processing: Numerical Modeling

Akbari,

Asadi,

Sadowski

2023

Materials

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Friction stir welding (FSW) is a manufacturing process that many industries have adopted to join metals in a solid state, resulting in unique properties. However, studying aspects like temperature distribution, stress distribution, and material flow experimentally is challenging due to severe plastic deformation in the weld zone. Therefore, numerical methods are utilized to investigate these parameters and gain a better understanding of the FSW process. Numerical models are employed to simulate material flow, temperature distribution, and stress state during welding. This allows for the identification of potential defect-prone zones. This paper presents a comprehensive review of research activities and advancements in numerical analysis techniques specifically designed for friction stir welding, with a focus on their applicability to component manufacturing. The paper begins by examining various types of numerical methods and modeling techniques used in FSW analysis, including finite element analysis, computational fluid dynamics, and other simulation approaches. The advantages and limitations of each method are discussed, providing insights into their suitability for FSW simulations. Furthermore, the paper delves into the crucial variables that play a significant role in the numerical modeling of the FSW process.

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“…The high rotational speed of FSW is attracting an increasing amount of attention. Mohan et al [24] combined µ-FSW with ultra-high rotational speed friction stir welding (ultra-HRS-FSW) to weld AA1100 with a thickness of 1.0 mm. The rotation speed of ultra-HRS-FSW ranges from 15,000 to 24,000 rpm.…”

Section: Introductionmentioning

confidence: 99%

On the Effects of High and Ultra-High Rotational Speeds on the Strength, Corrosion Resistance, and Microstructure during Friction Stir Welding of Al 6061-T6 and 316L SS Alloys

Chen

Meng

et al. 2021

Coatings

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In this study, under the conditions of using tools at a high rotational speed (HRS) of 10,000 rpm and an ultra-high rotational speed (ultra-HRS) of 18,000 rpm, the produced welding heat input was utilized to weld two specimens of Al alloy 6061-T6 with 1.0 mm thickness and 316L SS with 0.8 mm thickness. The microstructural characteristics, mechanical properties, and electrochemical corrosion properties of the aluminum alloy–steel joints were analyzed. The higher tool offset forms an intermetallic compound layer of less than 1 µm at the Fe-Al interface on the advancing side (AS) at different speeds. This results in a mixed zone structure. The lower tool offset forms intermetallic compounds of only 2 µm. The formation of a composite material based on aluminum alloy in the weld nugget zone improves the hardness value. The intermetallic compounds are Fe3Al and FeAl3, respectively. It was observed that the formation of intermetallic compounds is solely related to the rotational speed, and the iron-rich intermetallic compounds produced under ultra-HRS parameters have higher corrosion resistance. When the tool offset is 0.55 mm, using the HRS parameters, the tensile strength is 220.8 MPa (about 75.9% of that of the base metal).

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CFD modelling of ultra-high rotational speed micro friction stir welding

Cited by 16 publications

References 24 publications

Recent Advances in CFD Simulations of Multiphase Flow Processes with Phase Change

Recent Advances in CFD Simulations of Multiphase Flow Processes with Phase Change

A Review on Friction Stir Welding/Processing: Numerical Modeling

On the Effects of High and Ultra-High Rotational Speeds on the Strength, Corrosion Resistance, and Microstructure during Friction Stir Welding of Al 6061-T6 and 316L SS Alloys

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