Heat generation during plunge stage in friction stir welding

Abstract

This paper deals with the heat generation in the Al alloy Al2024-T3 plate under different rotating speeds and plunge speeds during the plunge stage of friction stir welding (FSW). A three-dimensional finite element model (FEM) is developed in the commercial code ABAQUS/Explicit using the arbitrary Lagrangian-Eulerian formulation, the Johnson-Cook material law and Coulomb’s Law of friction. The heat generation in FSW can be divided into two parts: frictional heat generated by the tool and heat generated by material deformation near the pin and the tool shoulder region. Numerical results obtained in this work indicate a more prominent influence from the friction-generated heat. The slip rate of the tool relative to the workpiece material is related to this portion of heat. The material velocity, on the other hand, is related to the heat generated by plastic deformation. Increasing the plunging speed of the tool decreases the friction-generated heat and increases the amount of deformation-generated heat, while increasing the tool rotating speed has the opposite influence on both heat portions. Numerical results are compared with the experimental ones, in order to validate the numerical model, and a good agreement is obtained

Emerging Modeling and Simulation Techniques for Friction Stir Welding - A Review

“…Computer based models can offer a reasonable insight into certain verifiable trends or guidance on empirical research to assist further understanding of the process physics. Developed coupled thermal-mechanical model for total amount and the distribution of the heat flux Total heat generation proportional to rotating rate and heat flux distribution axis symmetric about the tool axis 2 Darko M. VELJI et al (2013) [27] Studied heat generation under different rotating and plunge speeds during the plunge stage…”

Influence of friction stir welding parameters on properties of 2024 T3 aluminium alloy joints

“…For most of the aluminium alloys, the temperature in the welding zone is within the range 430-500°C. In the second welding stage, the rotating tool is moving along the joining line and continues to generate heat by friction and plastic deformation in the welding zone, along with stirring the material of both plates [13][14][15][16][17]. This enables the materials heated to a high temperature to be mechanically stirred.…”

Influence of friction welding parameters on properties of the Al-Cu joint

“…The friction by welding plays a significant role in those researches, whether the matter is rotational continuous friction welding (when the cylindrical elements are welded) or the FSW (when the welded elements are plates or thin sheets). Friction welding of various materials was the subject of these authors previous research [1][2][3], as well as of certain other authors [4][5][6][7][8][9][10][11]. In those articles, it was shown that successful joining by friction welding could be done for different classes of steel [1][2][3][4][5], steels and other metals [6] or the light metals [7][8][9][10].…”

“…In those articles, it was shown that successful joining by friction welding could be done for different classes of steel [1][2][3][4][5], steels and other metals [6] or the light metals [7][8][9][10]. In addition, joints realized by classical friction welding, considered in this paper, can be compared to joints obtained by the friction stir welding procedure [11][12][13][14]. Joints obtained by either of the two mentioned friction welding processes exhibit advantages, compared to joints executed by some other welding procedure and it was proven that they could withstand successfully both static and dynamic loads in exploitation [13,14].…”