Investigation of the effect of welding and rotational speed on strain and temperature during friction stir welding of AA5083 and AA7075 using the CEL approach

Abstract

In this study, the friction stir welding between AA5083 and AA7075 is modeled using numerical methods, and the role of parameters affecting the process, such as welding speed and rotation speed on material flow, temperature, and strain, is studied. The temperature, strain, and material mixing were analyzed while welding AA7075 to AA5083 alloys using a Coupled Eulerian-Lagrangian (CEL) approach. It was discovered that the CEL approach had accurately anticipated the mixing of materials in the stir zone (SZ) by comparing the SZ of the samples fabricated experimentally and modeled by simulation. Results show that the temperature and strain increase dramatically as the rotation speed increases from 500 to 900 rev/min. The material flow obtained from the simulation shows that with increasing rotational speed or decreasing welding speed, AA7075 is more stretched towards AA5083 in the sheet's higher surfaces, indicating an increase in material flow intensity. Better material mixing and increased material flow allowed for the achievement of the maximum tensile strength at the welding and rotation speeds of 36 mm/min and 900 rev/min.

A Review on Friction Stir Welding/Processing: Numerical Modeling

“…FSW represents an advanced iteration of the conventional friction welding process and was initially conceived by The Welding Institute (TWI) in 1991 [26,27]. Since then, it has emerged as a leading metal joining technique and is widely regarded as the most crucial development in this field over the past two decades.…”

Experimental Investigation and Characterization of Friction Stir Spot-Welded Dissimilar Aluminum Copper Metallic Lap Joints

“…Furthermore, the quantity of intermaterial mixing is greatly reduced when the tool traverse speed is increased. On the other hand, the production of intermetallic phases, which weakens the joint’s mechanical qualities, is constrained . By speeding up the welding process or slowing the rotation, the strain on the weld cross-section has been reduced.…”

“…On the other hand, the production of intermetallic phases, which weakens the joint’s mechanical qualities, is constrained. 12 By speeding up the welding process or slowing the rotation, the strain on the weld cross-section has been reduced. The strain also decreases when the temperature drops because there is less material flow.…”