Evaluation of welding characteristics using three-dimensional finite element simulation and experimentation for FSW of aluminum 6061

Rao, K. Venkata

doi:10.1007/s40430-018-0963-5

Cited by 3 publications

(3 citation statements)

References 24 publications

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“…Recently, many research studies are inclined toward solidstate welding which normally performs below the melting point of alloys includes friction stir welding (FSW), diffusion welding, pressure bases solid-state welding and brazing (Zn-based filler) as a solution for the above-stated problem [7]. One study utilized FSW to join AA6061 with magnesium alloy in order to minimize the formation of the brittle intermetallic compound at the interface.…”

Section: Page 2 Of 13mentioning

confidence: 99%

Modified utilization of semi-sectioned tubes as filler coated with MWCNTs–TiO2 in TIG arc welding to recover fusion lost mechanical properties of the weldment

Muzamil

Samiuddin

2018

J Braz. Soc. Mech. Sci. Eng.

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The loss of mechanical properties in heat treatable aluminum alloys categories during arc fusion welding processes is a critical issue, which limits the direct application in contrast to different post-treatments methods. This work involved a strategy for the novel and distinctive formation of fillers using 3-mm-diameter (AA6061) tubes having MWCNTs and TiO 2 nanoparticles coating on the inner surface. A series of experiments were conducted using TIG welding to evaluate the effect of welding current and composition of inside coating (MWCNTs-TiO 2) contents on welding strength. Three gradually increasing current values (160 A, 180 A and 200 A) were selected and tested against three combinations of nanocomposite coatings that include 1 wt% MWCNTs-TiO 2 , 1.5 wt% MWCNTs-TiO 2 and 2 wt% MWCNTs-TiO 2. Acceptable qualified bonding between nanocomposite and inside surface is utmost important before conducting the experiments, Tape Test (ASTM-D3359-09 e2) was performed for the assessment of bonding conditions and led to qualitatively exceptional bonding conditions after applying vacuum heating cycle. Tensile test results have demonstrated a significant improvement of 34.20-45.65% strength using innovative nanocomposite coated semi-sectioned tube in comparison to tube fillers without coating. Meanwhile, a beneficial gradually forming W-shape microhardness profile in contrast to conventional U and V shape profiles was achieved at 1.5 and 2 wt% of MWCNTs, and the uplift of hardness in the WZ region up to 86.51% subjected to increase high MWCNTs contents in combination with the current. Therefore, it is concluded to be a virtuous strategy for reinforcing mechanism of weldments to encounter some fusion property loss in aluminum alloys.

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Section: Page 2 Of 13mentioning

confidence: 99%

Modified utilization of semi-sectioned tubes as filler coated with MWCNTs–TiO2 in TIG arc welding to recover fusion lost mechanical properties of the weldment

Muzamil

Samiuddin

2018

J Braz. Soc. Mech. Sci. Eng.

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“…Up to now, much work has been done on the finite element method of the FSW process to study the thermal and mechanical properties, material flow velocity, viscosity profile, etc. 11–15 Nandan et al 16 investigated the numerical analysis to analyze the effect of temperature distribution, material flow, and cooling rate on microstructure properties during the FSW. They indicated that the shape and microstructure of the stir zone were affected by the aforementioned factors.…”

Section: Introductionmentioning

confidence: 99%

On the role of input welding parameters on the microstructure and mechanical properties of Al6061-T6 alloy during the friction stir welding: Experimental and numerical investigation

Bagheri

Sharifi

Abbasi

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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The Taguchi method was employed to find the optimum values of friction stir welding parameters including welding speed, rotating speed, and tilt angle for joining AA6061-T6 aluminum alloys. The combined influences of these parameters were entirely analyzed. Statistical outcomes were investigated by the study of variances and signal-to-noise ratios. A Coupled Eulerian and Lagrangian technique is implemented to simulate and verify the optimal parameters during the friction stir welding. To verify results, a comparison between the welding process under optimized parameters with experimental and non-optimized parameters was simulated for the friction stir welding process. The material flow, strain rate, thermal behaviors, and mechanical properties of samples fabricated with optimal welding parameters are higher than those produced from the non-optimal parameters. It was also concluded that the grain size of the stir zone under optimal welding parameters (6–8 µm) is finer than that of non-optimal welding parameters (11–13 µm). Low uniform distribution of material element and coarse microstructure were some of the results of welding with non-optimized parameters. Based on residual stress analysis, the application of optimal joining conditions can decrease the peak tensile residual stress by about 38.3%. The much desirable results obtained in terms of microstructure and mechanical properties could be of great significance to the welding industry.

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“…Primarily, FSW is applicable for joining low melting point materials such as aluminium alloys, copper and magnesium. The effects of the process parameters on the microstructure [1][2][3], thermal and mechanical properties of aluminium alloys [4][5][6][7] have been studied by several researchers. The feasibility of joining copper and dissimilar materials such as aluminium and copper has also been studied to investigate the optimum machining parameters on the mechanical properties of the materials [8,9].…”

Section: Introductionmentioning

confidence: 99%

An advanced modelling to improve the prediction of thermal distribution in friction stir welding (FSW) for difficult to weld materials

Sarikavak

2020

J Braz. Soc. Mech. Sci. Eng.

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This study explores the thermal distribution of high-strength engineering alloys during the friction stir welding process (FSW). Materials which are difficult to weld or are unweldable by conventional welding processes can be successfully welded by FSW. The specific analysis and modification of the process require an understanding of the actual mechanism of the process. Therefore, a transient, three-dimensional, thermo-mechanical finite element model (FEM) for FSW was developed. The model calculates the temperature distribution during the welding process considering various boundary conditions such as rotational speed, linear speed, normal pressure, tool diameter and material properties. The thermo-mechanical FEM calculations consider the effects of conduction and convection heat transfer. The numerical results are successfully compared and validated by experimental results published in the literature for aluminium alloy, titanium alloy and steel (mild and bainitic) as workpiece materials. The model was found to be useful for understanding the effects of changes in different system parameters, and for selecting the optimum welding conditions before undertaking high-cost physical testing.

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Evaluation of welding characteristics using three-dimensional finite element simulation and experimentation for FSW of aluminum 6061

Cited by 3 publications

References 24 publications

Modified utilization of semi-sectioned tubes as filler coated with MWCNTs–TiO2 in TIG arc welding to recover fusion lost mechanical properties of the weldment

Modified utilization of semi-sectioned tubes as filler coated with MWCNTs–TiO2 in TIG arc welding to recover fusion lost mechanical properties of the weldment

On the role of input welding parameters on the microstructure and mechanical properties of Al6061-T6 alloy during the friction stir welding: Experimental and numerical investigation

An advanced modelling to improve the prediction of thermal distribution in friction stir welding (FSW) for difficult to weld materials

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