Finite element modeling of friction stir welding (FSW) on a complex curved plate

Meyghani, Bahman; Awang, Mokhtar; Chen, Wu

doi:10.1016/j.jajp.2020.100007

Cited by 17 publications

(7 citation statements)

References 30 publications

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“…Meanwhile, the relationship between the welding parameters and the mechanical properties of the joints is highly non-linear [186,187]. Furthermore, despite the diffusion of five-axis numerically controlled machines, the equipment is limited for studying complicated geometries [188]. Consequently, a deep investigation is still challenging [189].…”

Section: Design Toolmentioning

confidence: 99%

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

Bella

Favaloro

Borsellino

2023

Metals

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Friction Stir Welding is a suitable solid-state joining technology to connect dissimilar materials. To produce an effective joint, a phase of optimization is required which leads to the definition of process parameters such as pin geometry, tool rotational speed, rotation direction, welding speed, thickness of the sheets or tool tilt angle. The aim of this review is to present a complete and detailed frame of the main process parameters and their effect on the final performance of a friction stir welded joint in terms of mechanical properties and microstructure. Attention was focused in particular on the connection between different aluminum alloys. Moreover, the experimental results were correlated to the development and the applications of tools which can be effectively used in the design of the manufacturing process such as finite element analyses, artificial neural networks, and statistical studies. The review also aims to be a point of reference to identify the best combinations of process parameters based on the dissimilar aluminum to be joined.

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Section: Design Toolmentioning

confidence: 99%

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

Bella

Favaloro

Borsellino

2023

Metals

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“…In order to focus on the role of axial force on curved lap joint, the model only considered the axial force loading process occurring at the stage of stable welding (the most critical stage of weld forming), ignoring the thermal process, plastic ow and other mechanical effort in other stages of welding. This assumption may cause some inaccuracies, but these inaccuracies can be ignored in terms of studying the in uence of axial force on joint stress and deformation [26][27][28][29][30].…”

Section: Axial Force Loading Process Simulation Modelmentioning

confidence: 99%

Effects of curvature direction on friction stir welding lap joint of aluminum alloy “S” curved surface

Xiao

Mao²,

Wang³

et al. 2023

Int J Adv Manuf Technol

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In this paper, the friction stir welding (FSW) of single-curvature and double-curvature "S" curved surface lap joints were realized using split type pressing blocks xture and robotic system with welding parameter 1400rpm, 150mm/min. By Finite Element Method (FEM) and axial force analysis, the effects of curvature direction on friction stir welding lap joint of 5083 Aluminum Alloy "S" Curved surface is explored. The results show that Z-axis curvature direction has important in uence on joint forming. By split type pressing blocks xture, the material thermal expansion causes upward force F' in Z-axis positive curvature position, but causes downward force F' in Z-axis negative curvature position. So Z-axis positive curvature makes the actual axial compressive force F R (F R =F N -F') smaller than the device input F N . Which decreases the interface stress of the lap joint and increases the tendency of upper plate edges bending deformation and the probability of interface defects. Finally, the joint mechanical properties are reduced, the tensile load can be as low as 1.5 kN. While Z-axis negative curvature makes the actual axial compressive force F R (F R =F N +F') greater than the device input F N . Which increases the interface stress of the lap joint. Meanwhile it decreases the tendency of upper plate edges bending deformation and leads to the interface defects disappearing. So the joint mechanical properties are good, the tensile load can be more than 2.4 kN. For Y-axis curvature direction, its impact is mainly shown in changing the direction of resultant force F R . In Y-axis positive curvature position, the force F R lies between Y positive direction and Z negative direction. While in Y-axis negative curvature position, the force F R lies between Y negative direction and Z negative direction. The inclination of force F R is helpful to eliminate the interface defects of the joint. At the same time, it will cause inconsistent stress between the advancing side (AS) and the retreating side (RS) of the joint interface, which is the reason that the double-curvature lap joint welding process is unstable.

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Section: Axial Force Loading Process Simulation Modelmentioning

confidence: 99%

Effects of Curvature Direction on Friction Stir Welding Lap Joint of Aluminum Alloy "S" Curved Surface

Xiao

Mao²,

Wang³

et al. 2023

Preprint

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In this paper, the friction stir welding (FSW) of single-curvature and double-curvature "S" curved surface lap joints were realized using split type pressing blocks fixture and robotic system with welding parameter 1400rpm, 150mm/min. By Finite Element Method (FEM) and axial force analysis, the effects of curvature direction on friction stir welding lap joint of 5083 Aluminum Alloy "S" Curved surface is explored. The results show that Z-axis curvature direction has important influence on joint forming. By split type pressing blocks fixture, the material thermal expansion causes upward force F’ in Z-axis positive curvature position, but causes downward force F’ in Z-axis negative curvature position. So Z-axis positive curvature makes the actual axial compressive force FR (FR=FN-F’) smaller than the device input FN. Which decreases the interface stress of the lap joint and increases the tendency of upper plate edges bending deformation and the probability of interface defects. Finally, the joint mechanical properties are reduced, the tensile load can be as low as 1.5 kN. While Z-axis negative curvature makes the actual axial compressive force FR (FR=FN+F’) greater than the device input FN. Which increases the interface stress of the lap joint. Meanwhile it decreases the tendency of upper plate edges bending deformation and leads to the interface defects disappearing. So the joint mechanical properties are good, the tensile load can be more than 2.4 kN. For Y-axis curvature direction, its impact is mainly shown in changing the direction of resultant force FR. In Y-axis positive curvature position, the force FR lies between Y positive direction and Z negative direction. While in Y-axis negative curvature position, the force FR lies between Y negative direction and Z negative direction. The inclination of force FR is helpful to eliminate the interface defects of the joint. At the same time, it will cause inconsistent stress between the advancing side (AS) and the retreating side (RS) of the joint interface, which is the reason that the double-curvature lap joint welding process is unstable.

show abstract

Finite element modeling of friction stir welding (FSW) on a complex curved plate

Cited by 17 publications

References 30 publications

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

Effects of curvature direction on friction stir welding lap joint of aluminum alloy “S” curved surface

Effects of Curvature Direction on Friction Stir Welding Lap Joint of Aluminum Alloy "S" Curved Surface

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