Effect of Pin Shape on Thermal History of Aluminum-Steel Friction Stir Welded Joint: Computational Fluid Dynamic Modeling and Validation

Jawad, Mohammed Abed; Suksatan, Wanich; Abdullah, Mahmoud E.; Świerczyńska, Aleksandra; Fydrych, Dariusz; Derazkola, Hamed Aghajani

doi:10.3390/ma14247883

Cited by 44 publications

(17 citation statements)

References 77 publications

(73 reference statements)

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“…In general, in the FSW of dissimilar materials, the portion of participation of materials determines the joint properties [ 42 , 43 ]. Imbalance in the volume ratio of plastic flow leads to inappropriate material mixing at weld nugget and finally increment in defects density [ 44 , 45 , 46 ]. The tool offset in the dissimilar joint is an essential issue because it increases FSW tool life and base metal mixing.…”

Section: Resultsmentioning

confidence: 99%

Effect of Tool Positioning Factors on the Strength of Dissimilar Friction Stir Welded Joints of AA7075-T6 and AA6061-T6

et al. 2022

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Friction Stir Welding (FSW) is a solid-state bonding technique. There are many direct and indirect factors affecting the mechanical and microstructural properties of the FSW joints. Tool offset, tilt angle, and plunge depth are determinative tool positioning in the FSW process. Investigating the effect of these factors simultaneously with other parameters such as process speeds (rotational speed and translational speed) and tool geometry leads to a poor understanding of the impact of these factors on the FSW process. Because the three mentioned parameters have the same origin, they should be studied separately from other process parameters. This paper investigates the effects of tilt angle, plunge depth, and tool offset on Ultimate Tensile Stress (UTS) of joints between AA6061-T6 and AA7075-T6. To design the experiments, optimization, and statistical analysis, Response Surface Methodology (RSM) has been used. Experimental tests were carried out to find the maximum achievable UTS of the joint. The optimum values were determined based on the optimization procedure as 0.7 mm of tool offset, 2.7 degrees of tilt angle, and 0.1 mm of plunge depth. These values resulted in a UTS of 281 MPa. Compared to the UTS of base metals, the joint efficiency of the optimized welded sample was nearly 90 percent.

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Section: Resultsmentioning

confidence: 99%

Effect of Tool Positioning Factors on the Strength of Dissimilar Friction Stir Welded Joints of AA7075-T6 and AA6061-T6

et al. 2022

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“…At the bottom surface, the local temperature governed the heat transfer coefficient according to the following equation [43]:…”

Section: Heat Transfer Modelmentioning

confidence: 99%

Effects of Noncontact Shoulder Tool Velocities on Friction Stir Joining of Polyamide 6 (PA6)

et al. 2022

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In this study, the effects of the traverse and rotational velocities of the noncontact shoulder tool on the heat generation and heated flux during the friction stir joining of high-density polyamide 6 (PA6) polymer were investigated. The computational fluid dynamics (CFD) method was employed to simulate the thermomechanical phenomena during the friction stir joining (FSJ) process of PA6. A developed model was used to consider the void formation and thermochemical properties of PA6. The surface and internal heat flow, material flow, and geometry of the joint were simulated, and an experimental study evaluated the simulation results. The simulation results indicated that the stir zone formed was smaller than regular joints with a noncontact shoulder tool. Despite the polymer’s traditional FSJ, heat generation and material flow do not differ significantly between advancing and retreating sides. On the other hand, the surface flow is not formed, and the surface temperature gradient is in a narrow line behind the tool. The material velocity increased at higher rotational speed and lower transverse velocity and in the stir zone with more giant geometry forms. The maximum generated heat was 204 °C, and the maximum material velocity was predicted at 0.44 m/s in the stir zone, achieved at 440 rpm and 40 mm/min tool velocities.

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“…Based on Figure 8, it was found that increasing plunge depth led to a significant increase in the maximum temperature of the FSW process. In general, friction and plastic flow created in the FSW process result in heat generation in the weld zone [57,58]. Generated heat produced by the aforementioned factors significantly changes with plunge depth.…”

Section: Plunge Depth Effectmentioning

confidence: 99%

Investigation of the Effects of Tool Positioning Factors on Peak Temperature in Dissimilar Friction Stir Welding of AA6061-T6 and AA7075-T6 Aluminum Alloys

et al. 2022

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Among the emerging new welding techniques, friction stir welding (FSW) is used frequently for welding high-strength aluminum alloys that are difficult to weld by conventional fusion-welding techniques. This paper investigated the effects of tool-positioning factors on the maximum temperature generated in the dissimilar FSW joint of AA6061-T6 and AA7075-T6 aluminum alloys. Three factors of plunge depth, tool offset, and tilt angle were used as the input parameters. Numerical simulation of the FSW process was performed in ABAQUS software using the coupled Eulerian–Lagrangian (CEL) approach. Central composite design (CCD) based on response surface methodology (RSM) was used to analyze and design the experiments. Comparison of the numerical and experimental results showed that numerical simulations were in good agreement with the experimental ones. Based on the statistical model results, plunge depth, tilt angle, and tool offset were the most significant factors on maximum process temperature, respectively. It was found that increasing the plunge depth caused a sharp increase in the maximum process temperature due to increased contact surfaces and the frictional interaction between the tool and workpiece.

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Effect of Pin Shape on Thermal History of Aluminum-Steel Friction Stir Welded Joint: Computational Fluid Dynamic Modeling and Validation

Cited by 44 publications

References 77 publications

Effect of Tool Positioning Factors on the Strength of Dissimilar Friction Stir Welded Joints of AA7075-T6 and AA6061-T6

Effect of Tool Positioning Factors on the Strength of Dissimilar Friction Stir Welded Joints of AA7075-T6 and AA6061-T6

Effects of Noncontact Shoulder Tool Velocities on Friction Stir Joining of Polyamide 6 (PA6)

Investigation of the Effects of Tool Positioning Factors on Peak Temperature in Dissimilar Friction Stir Welding of AA6061-T6 and AA7075-T6 Aluminum Alloys

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