Comparison Between ALE and CEL Finite Element Formulations to Simulate Friction Stir Spot Welding

Hannachi, Nasra; Khalfallah, Ali; Leitão, C.; Rodrigues, D.M.

doi:10.1007/978-3-030-86446-0_36

Cited by 6 publications

(3 citation statements)

References 8 publications

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“…The study found that this extension was valuable in comprehending the physics of FSW, including the transition from contact to continuum, along with other complex phenomena. Hannachi et al [128] conducted a comparison between the ALE and CEL methods in the numerical simulation of the three-dimensional FSSW process of an AA6082-T6 aluminum alloy. Their findings revealed that the CEL modeling technique was not only more accurate, but also simpler to use and more computationally efficient in comparison to the ALE modeling technique.…”

Section: Initial Statementioning

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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Section: Initial Statementioning

confidence: 99%

A Review on Friction Stir Welding/Processing: Numerical Modeling

Akbari,

Asadi,

Sadowski

2023

Materials

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“…During the plunging phase, the maximum temperature recorded was 300°C, indicating the thermal effects of the process. Furthermore, they checked and compared the level of efficiency and accuracy of both Lagrangian-Eulerian (ALE) and Coupled Eulerian-Lagrangian (CEL) methods that were used to simulate the FSSW of aluminum alloy using Abaqus software [ 13 ].…”

Section: Introductionmentioning

confidence: 99%

Numerical and Experimental Analyses of Developed Friction Stir Spot Welding (DFSSW) Based on Systematic Design Process Approach

Abd Al-Sahb,

Hussein,

Mohammed

et al. 2024

The Scientific World Journal

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This research paper presents a developed technique for Friction Stir Spot Welding (FSSW) to join similar aluminum sheets (6061), and then this technique was analyzed critically based on numerical simulation and experimental work. The objective of this Developed Friction Stir Spot Welding (DFSSW) is to avoid or at least reduce the keyhole defects by optimizing the design parameters of the process. The coupling problem (thermomechanical) was solved numerically using the finite element method to find the variations of temperatures and stress distributions in addition to the applied forces by the tool. Different parameters were considered in the numerical analysis, such as rotational speed and plunge depth. The experimental results proved the success of the developed technique by comparing the available results of tensile shear force with the results of other researchers that applied the traditional FSSW. It was obtained the highest tensile shear force (2388 N) under the optimal working and design conditions, when the rotational speed, plunging depth, height, and diameter of the sliced disc were 2100 rpm, 0.3 mm, 3.5 mm, and 12 mm, respectively. It was found that both the diameter and height of the sliced disc are significant parameters that ensure the success of this new technique when selecting the suitable values for these parameters. Otherwise, selecting unsuitable values of these parameters leads to appearing defects (e.g., flash) or the sample will fail under a low level of tensile shear force. The other essential advantage outcome point of this new technique was reducing the defect of the keyhole significantly compared with the results of typical Friction Stir Spot Welding. According to the results of the promising developed welding procedure that can be automated, it can be used widely in the industrial sectors.

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“…They stated that friction stir spot welding could be effectively numerically analyzed if the interfacial friction characteristics are correctly modeled. Hannachi et al [35] compared the ALE and CEL methods' capability in modeling friction stir spot welding of an AA6082-T6 aluminum alloy. Comparing CEL modeling to ALE modeling, CEL is more accurate, computationally efficient, and easier to use.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the effect of welding and rotational speed on strain and temperature during friction stir welding of AA5083 and AA7075 using the CEL approach

Akbari

RahimiAsiabaraki

Aliha³

2023

Eng. Res. Express

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In this study, the friction stir welding between AA5083 and AA7075 is modeled using numerical methods, and the role of parameters affecting the process, such as welding speed and rotation speed on material flow, temperature, and strain, is studied. The temperature, strain, and material mixing were analyzed while welding AA7075 to AA5083 alloys using a Coupled Eulerian-Lagrangian (CEL) approach. It was discovered that the CEL approach had accurately anticipated the mixing of materials in the stir zone (SZ) by comparing the SZ of the samples fabricated experimentally and modeled by simulation. Results show that the temperature and strain increase dramatically as the rotation speed increases from 500 to 900 rev/min. The material flow obtained from the simulation shows that with increasing rotational speed or decreasing welding speed, AA7075 is more stretched towards AA5083 in the sheet's higher surfaces, indicating an increase in material flow intensity. Better material mixing and increased material flow allowed for the achievement of the maximum tensile strength at the welding and rotation speeds of 36 mm/min and 900 rev/min.

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Comparison Between ALE and CEL Finite Element Formulations to Simulate Friction Stir Spot Welding

Cited by 6 publications

References 8 publications

A Review on Friction Stir Welding/Processing: Numerical Modeling

A Review on Friction Stir Welding/Processing: Numerical Modeling

Numerical and Experimental Analyses of Developed Friction Stir Spot Welding (DFSSW) Based on Systematic Design Process Approach

Investigation of the effect of welding and rotational speed on strain and temperature during friction stir welding of AA5083 and AA7075 using the CEL approach

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