Friction Spot Extrusion Welding on Dissimilar Materials AA2024-T3 to AA5754-O: Effect of Shoulder Plunge Depth

Memon, Shabbir; Paidar, Moslem; Mehta, Kush P.; Babaei, Behzad; Lankarani, Hamid M.

doi:10.1007/s11665-020-05387-4

Cited by 25 publications

(11 citation statements)

References 40 publications

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“…The results indicate that the St-14 steel stretched into the aluminum side and AA1100 alloy and diffused into the steel side from the middle of the joint-this stir zone shape formed in both samples. The wavy shape interface can be seen in the SEM image that shows the mechanical interlocking formed in the interface of base metals [1,55,[63][64][65][66][67]. The small hooks formed in the upper and lower area of the stir zone.…”

Section: Internal Heat Flowmentioning

confidence: 98%

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

et al. 2021

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This article studied the effects of pin angle on heat generation and temperature distribution during friction stir welding (FSW) of AA1100 aluminum alloy and St-14 low carbon steel. A validated computational fluid dynamics (CFD) model was implemented to simulate the FSW process. Scanning electron microscopy (SEM) was employed in order to investigate internal materials’ flow. Simulation results revealed that the mechanical work on the joint line increased with the pin angle and larger stir zone forms. The simulation results show that in the angled pin tool, more than 26% of the total heat is produced by the pin. Meanwhile, in other cases, the total heat produced by the pin was near 15% of the total generated heat. The thermo-mechanical cycle in the steel zone increased, and consequently, mechanical interlock between base metals increased. The simulation output demonstrated that the frictional heat generation with a tool without a pin angle is higher than an angled pin. The calculation result also shows that the maximum heat was generated on the steel side.

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Section: Internal Heat Flowmentioning

confidence: 98%

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

et al. 2021

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“…In the past, many researchers considered the production of T-joints with the various conventional welding processes. These joints had many defects during traditional welding processes [ 6 , 7 , 8 , 9 , 10 ].…”

Section: Introductionmentioning

confidence: 99%

“…Low TPD decreases friction contact between the tool and the workpiece, and high TPD decreases SZ size due to the formation of high surface flash around the joint line. Thus, optimization of TPD to analyze material flow and avoid void formation is critical [ 7 , 21 , 22 ].…”

Section: Introductionmentioning

confidence: 99%

Effects of FSW Tool Plunge Depth on Properties of an Al-Mg-Si Alloy T-Joint: Thermomechanical Modeling and Experimental Evaluation

et al. 2021

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One of the main challenging issues in friction stir welding (FSW) of stiffened structures is maximizing skin and flange mixing. Among the various parameters in FSW that can affect the quality of mixing between skin and flange is tool plunge depth (TPD). In this research, the effects of TPD during FSW of an Al-Mg-Si alloy T-joint are investigated. The computational fluid dynamics (CFD) method can help understand TPD effects on FSW of the T-joint structure. For this reason, the CFD method is employed in the simulation of heat generation, heat distribution, material flow, and defect formation during welding processes at various TPD. CFD is a powerful method that can simulate phenomena during the mixing of flange and skin that are hard to assess experimentally. For the evaluation of FSW joints, macrostructure visualization is carried out. Simulation results showed that at higher TPD, more frictional heat is generated and causes the formation of a bigger stir zone. The temperature distribution is antisymmetric to the welding line, and the concentration of heat on the advancing side (AS) is more than the retreating side (RS). Simulation results from viscosity changes and material velocity study on the stir zone indicated that the possibility of the formation of a tunnel defect on the skin–flange interface at the RS is very high. Material flow and defect formation are very sensitive to TPD. Low TPD creates internal defects with incomplete mixing of skin and flange, and high TPD forms surface flash. Higher TPD increases frictional heat and axial force that diminish the mixing of skin and flange in this joint. The optimum TPD was selected due to the best materials flow and final mechanical properties of joints.

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“…In this situation, the base metal undergoes thermo-mechanical deformation (TMD) by rotational movement of the FSW tool inside of BS. With TMD, fine and equiaxed re-crystallized microstructures form in the joint line and improve the final properties of welded samples [ 6 , 7 , 8 , 9 , 10 , 11 ].…”

Section: Introductionmentioning

confidence: 99%

Thermo-Mechanical Simulation of Underwater Friction Stir Welding of Low Carbon Steel

2021

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This article investigates the flow of materials and weld formation during underwater friction stir welding (UFSW) of low carbon steel. A thermo-mechanical model is used to understand the relation between frictional heat phenomena during the welding and weld properties. To better understand the effects of the water environment, the simulation and experimental results were compared with the sample prepared by the traditional friction stir welding (FSW) method. Simulation results from surface heat diffusion indicate a smaller preheated area in front of the FSW tool declined the total generated heat in the UFSWed case compared to the FSWed sample. The simulation results revealed that the strain rate of steel in the stir zone (SZ) of the FSWed joint is higher than in the UFSWed case. The microstructure of the welded sample shows that SZ’s microstructure at the UFSWed case is more refined than the FSWed case due to the higher cooling rate of the water environment. Due to obtained results, the maximum temperatures of FSWed and UFSWed cases were 1228 °C and 1008 °C. Meanwhile, the simulation results show 1200 °C and 970 °C for conventional and underwater FSW samples, respectively. The maximum material velocity in SZ predicted 0.40 m/s and 0.32 m/s for FSW and underwater FSWed samples. The better condition in the UFSW case caused the ultimate tensile strength of welded sample to increase ~20% compared to the FSW joint.

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Friction Spot Extrusion Welding on Dissimilar Materials AA2024-T3 to AA5754-O: Effect of Shoulder Plunge Depth

Cited by 25 publications

References 40 publications

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

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

Effects of FSW Tool Plunge Depth on Properties of an Al-Mg-Si Alloy T-Joint: Thermomechanical Modeling and Experimental Evaluation

Thermo-Mechanical Simulation of Underwater Friction Stir Welding of Low Carbon Steel

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