Heat Transfer Simulation and Effect of Tool Pin Profile and Rotational Speed on Mechanical Properties of Friction Stir Welded AA5083-O

Elsayed, Mohamed L.; Shash, Ahmed Y.; Rabou, Mahmoud Abd

doi:10.5781/jwj.2017.35.3.6

Cited by 7 publications

(4 citation statements)

References 10 publications

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“…The greatest peak temperature value is obtained at a tool rotating speed of 700 rpm due to the increased heat flux value, as shown in the figure. The peak temperature rises as the tool's rotational speed increases [29].…”

Section: The Influence Of Tool Rotational Speedmentioning

confidence: 99%

Modeling and Simulation of Friction Stir Welding of Aluminum and Magnesium Alloys Using Finite Element Analysis

Efa,

Gutema,

Lemu

et al. 2024

KEM

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The aviation and automobile sectors have witnessed significant expansion and demand for lightweight metals. The friction stir welding (FSW) procedure is used for joining lightweight and low melting temperature materials. A Finite Element Analysis (FEA) utilising COMSOL® Multiphysics 6.0 software is utilised in this article to combine dissimilar metals AA6061-T6 and Mg AZ31-B, and their thermo-mechanical characteristics are explored. The peak temperature was observed to increase to 448K and 928K when the coefficient of friction (COF) increased from 0.01 to 0.4, while other parameters remained constant. When the tool rotational speed is increased to 500, 600, or 700 rpm, the peak temperature climbs to 658 K, 706 K, and 759 K, while all other parameters stay constant. When the welding speed is increased, the peak temperature reduces from 665K, 649K, and 638K to 45mm/min, 60mm/min, and 75mm/min, with all other parameters remained constant in this study. The peak temperature climbed to 632K, 684K, and 759K when the axial force increased to 10 kN, 15 kN, and 20 kN, respectively, which is a tolerable temperature less than the point of melting of materials. Peak temperatures increase to 628K, 630K, and 635K when the shoulder-to-pin diameter ratio increases to 2.5, 3.0 and 3.5 with all other parameters remaining constant. As a result, the peak temperature is directly related to tool rotational speed, coefficient of friction, axial force, and shoulder-to-pin diameter ratio, whereas welding speed is inversely proportional.

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Section: The Influence Of Tool Rotational Speedmentioning

confidence: 99%

Modeling and Simulation of Friction Stir Welding of Aluminum and Magnesium Alloys Using Finite Element Analysis

Efa,

Gutema,

Lemu

et al. 2024

KEM

View full text Add to dashboard Cite

show abstract

“…In recent years, new geometric features have been developed in the design of the FSW tools 6,17) . Under the influence of many features of the tools, the movement of matter around the shoulder can be different from one tool to another depending on the tool features 18) . The shape, tilt, length, and diameter of the tool are very important parameters in providing the speed and quality of the FSW process 19) .…”

Section: Investigating the Effect Of Different Parameters On The Fricmentioning

confidence: 99%

Investigation of Spindle Rotation Rate Effects on the Mechanical Behavior of Friction Stir Welded Ti 4Al 2V Alloy

Aali

2020

Journal of Welding and Joining

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Nowadays, titanium and its alloys are widely utilized in various industrial parts in such areas as the petrochemical, medical, and automotive industries; However, due to structural considerations, application is problematic in cases of joining. Ti 4Al 2V is a new type of titanium alloy, that in point of structure is near to the α-series, which have many applications in critical conditions (moisture, steam, temperature, etc.). One of the main drawbacks of titanium is the welding of this alloy; however, friction stir welding has been found to be a good method in joining solid materials, especially titanium and its alloys. In this research, the effective parameter of spindle rotational rate has been varied through the process and its effect on the mechanical properties was examined.

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“…This study implemented simulations conducting BOP (Bead on Plate) tests on mild steel, using Abaqus (Dassault Systems) as the FEM software for the simulations and Fortran to implement the moving heat source. The performance of the software above has been verified and is widely used in research using welding simulations [19][20][21][22].…”

Section: Introductionmentioning

confidence: 95%

Estimation of Heat Source Model’s Parameters for GMAW with Non-linear Global Optimization—Part I: Application of Multi-island Genetic Algorithm

Pyo

Kim

2020

Metals

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Estimating the thermo-elasto-plastic deformation by arc welding through finite element analysis has been used in various industrial fields. The Goldak heat source model is one of the most important and widely used models in finite element analysis, and its parameters are estimated based on the results of previous studies and tests. Part I of this study focused on the adequate heat source model, and the study for the welding deformation with the moving heat source will be done on the latter research. This study used the parameters of Goldak’s heat source model, weld efficiency, and the location of the heat source as design variables, and defined the Heat Affected Zone (HAZ) boundary line of Bead on Plate (BOP) welding as the target. BOP welding was performed using SS400 plates, the HAZ boundary line was determined based on examining the shape of the cross-section, and the optimization condition was that temperature inside the boundary line exceeded 727 °C while the temperature outside the line did not exceed 727 °C during the welding process. During this process, a multi-island genetic algorithm (non-linear global optimization method) was used to obtain the optimal results out of 1000 candidate groups, in which the HAZ boundary was similar to the experimental results. Applying a global optimization algorithm to determine the parameters of the most important heat source model to analyze welding deformation is significant, and this may be applied in various industrial fields that use welding including shipbuilding, aviation, and machinery industries.

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Heat Transfer Simulation and Effect of Tool Pin Profile and Rotational Speed on Mechanical Properties of Friction Stir Welded AA5083-O

Cited by 7 publications

References 10 publications

Modeling and Simulation of Friction Stir Welding of Aluminum and Magnesium Alloys Using Finite Element Analysis

Modeling and Simulation of Friction Stir Welding of Aluminum and Magnesium Alloys Using Finite Element Analysis

Investigation of Spindle Rotation Rate Effects on the Mechanical Behavior of Friction Stir Welded Ti 4Al 2V Alloy

Estimation of Heat Source Model’s Parameters for GMAW with Non-linear Global Optimization—Part I: Application of Multi-island Genetic Algorithm

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