Numerical simulation of friction stir spot welding process for aluminum alloys

Kim, Dongun; Badarinarayan, H.; Ryu, Ill; Kim, Ji Hoon; Kim, Chongmin; Okamoto, K.; Wagoner, R. H.; Chung, Kwansoo

doi:10.1007/s12540-010-0425-9

Cited by 29 publications

(16 citation statements)

References 11 publications

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“…Kim et al [70] utilized two ways to develop thermomechanical simulations of AA5083-H18 and AA6022-T4. The two methods were commercial finite element method (FEM) based on Lagrangian and finite volume method (FVM) based on Eulerian formulations.…”

Section: Modelling Of the Fssw Processmentioning

confidence: 99%

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Friction Stir Spot Welding: A Review on Joint Macro- and Microstructure, Property, and Process Modelling

Yang

Tian

2014

Advances in Materials Science and Engineering

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Friction stir spot welding (FSSW) is a very useful variant of the conventional friction stir welding (FSW), which shows great potential to be a replacement of single-point joining processes like resistance spot welding and riveting. There have been many reports and some industrial applications about FSSW. Based on the open literatures, the process features and variants, macro- and microstructural characteristics, and mechanical properties of the resultant joints and numerical simulations of the FSSW process were summarized. In addition, some applications of FSSW in aerospace, aviation, and automobile industries were also reviewed. Finally, the current problems and issues that existed in FSSW were indicated.

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Section: Modelling Of the Fssw Processmentioning

confidence: 99%

“…The two methods were commercial finite element method (FEM) based on Lagrangian and finite volume method (FVM) based on Eulerian formulations. The effect of pin geometry on weld strength and material flow was understood by simulation [70].…”

Section: Modelling Of the Fssw Processmentioning

confidence: 99%

Friction Stir Spot Welding: A Review on Joint Macro- and Microstructure, Property, and Process Modelling

Yang

Tian

2014

Advances in Materials Science and Engineering

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“…This paper presents a thermal-only implicit FE model of pinless FSSW, allowing time-efficient parametric studies and reverse engineering of heat generation. Most FSSW modelers assume either sticking at the interface (Ref 16,18), or a Coulomb friction law with a constant (Ref 21-23, 26-28, 31) or temperature-dependent coefficient of friction (Ref 24,29,30). With few exceptions (Ref 20,28), no independent machine torque or power measurements have been provided to validate the assumed contact model.…”

Section: Introductionmentioning

confidence: 99%

Thermal Modeling of Al-Al and Al-Steel Friction Stir Spot Welding

Jedrasiak

Shercliff

Reilly

et al. 2016

J. of Materi Eng and Perform

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This paper presents a finite element thermal model for similar and dissimilar alloy friction stir spot welding (FSSW). The model is calibrated and validated using instrumented lap joints in Al-Al and Al-Fe automotive sheet alloys. The model successfully predicts the thermal histories for a range of process conditions. The resulting temperature histories are used to predict the growth of intermetallic phases at the interface in Al-Fe welds. Temperature predictions were used to study the evolution of hardness of a precipitation-hardened aluminum alloy during post-weld aging after FSSW.

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“…Because of the increase of the joining area, the maximum fracture load of such joint is 110% higher than that of the traditional FSSW joint under the same welding parameters. The fracture load of these joints depends on the joining width, including the width of solid-state bonding region in stir zone and brazing region out of stir zone.optimize the mechanical properties of the joint [17][18][19][20][21]. Unavoidably, the traditional FSSW would leave a keyhole that reduces its bonding area [22].…”

mentioning

confidence: 99%

“…optimize the mechanical properties of the joint [17][18][19][20][21]. Unavoidably, the traditional FSSW would leave a keyhole that reduces its bonding area [22].…”

mentioning

confidence: 99%

Friction Stir Spot Welding-Brazing of Al and Hot-Dip Aluminized Ti Alloy with Zn Interlayer

Zhou

Chen

et al. 2018

Metals

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Friction stir spot welding (FSSW) of Al to Ti alloys has broad applications in the aerospace and automobile industries, while its narrow joining area limits the improvement of mechanical properties of the joint. In the current study, an Al-coating was prepared on Ti6Al4V alloy by hot-dipping prior to joining, then a Zn interlayer was used during friction stir joining of as-coated Ti alloy to the 2014-Al alloy in a lap configuration to introduce a brazing zone out of the stir zone to increase the joining area. The microstructure of the joint was investigated, and the joint strength was compared with the traditional FSSW joint to confirm the advantages of this new process. Because of the increase of the joining area, the maximum fracture load of such joint is 110% higher than that of the traditional FSSW joint under the same welding parameters. The fracture load of these joints depends on the joining width, including the width of solid-state bonding region in stir zone and brazing region out of stir zone.optimize the mechanical properties of the joint [17][18][19][20][21]. Unavoidably, the traditional FSSW would leave a keyhole that reduces its bonding area [22]. Although some modified processes for FSSW, such as refill FSSW [23], flat FSSW [24], and short travel FSSW [25], have attempted to eliminate this visible keyhole, they are complicated and time-consuming owing to the rigorous welding conditions and/or complex tool design. Recently, friction stir brazing (FSSB) has been developed by using a pinless tool and adding brazing filler metal to induce metallurgical reaction at the interface with the aid of friction heat and forging pressure, instead of plastic flow [22]. This technique has successfully introduced a brazing zone in dissimilar joints of steel/Al [26], Cu/Al [27], and Al /Mg [28], while FSSB of Al and Ti alloys is yet to be reported.This work aims to find an effective approach to improve the joining area of the Al/Ti joint by combining FSSW and FSSB. Zinc (Zn) is an optional filler for FSSB of Al alloys as a result of its low melting point (420 • C), high solubility in Al, as well as absence of formation of IMCs in the Al-Zn alloying system [29][30][31][32]. During our preliminary study, a Zn interlayer was placed between the interface of 2014 Al and Ti6Al4V alloys for the FSSB process to determine their weldability. It was found that the high affinity of Ti towards oxygen led to the formation of non-protective oxide scales on the Ti6Al4V [33], resulting in poor wettability of Zn to Ti alloys and, therefore, failure to join Al and Ti alloys. Recently, using an electroplating process before the FSB process would produce a copper layer on the surface of graphite, which converted the graphite-copper lap joint to the similar joining of copper to copper [34]. This gives us an idea that pretreating the base metal will be a possible benefit for FSSB of Al and Ti.In the present paper, we utilized hot dip to aluminize T6Al4V alloys and developed a friction stir spot joining process, called friction stir spot w...

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Numerical simulation of friction stir spot welding process for aluminum alloys

Cited by 29 publications

References 11 publications

Friction Stir Spot Welding: A Review on Joint Macro- and Microstructure, Property, and Process Modelling

Friction Stir Spot Welding: A Review on Joint Macro- and Microstructure, Property, and Process Modelling

Thermal Modeling of Al-Al and Al-Steel Friction Stir Spot Welding

Friction Stir Spot Welding-Brazing of Al and Hot-Dip Aluminized Ti Alloy with Zn Interlayer

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