Numerical simulation of residual stresses for friction stir welds in copper canisters

Jin, Lai-Zhe; Sandström, Rolf

doi:10.1016/j.jmapro.2011.10.001

Cited by 19 publications

(4 citation statements)

References 12 publications

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“…Nonetheless, the existence of one case proves that the TPM model cannot predict the effect of tool radii on the residual stresses. Some researchers have suspected there would be parameters and conditions that the TPM model cannot predict, and they have used a similar calibration approach [30], [40]. It should be noted that the calibrated TPM model can still predict the effect of process parameters (row 2 in Fig.…”

Section: Resultsmentioning

confidence: 99%

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On the Utility of the Thermal-Pseudo Mechanical Model’s Residual Stress Prediction Capability for the Development of Friction Stir Processing

Balusu

Choi

Das

et al. 2023

Int J Adv Manuf Technol

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This paper investigates the thermal-pseudo mechanical (TPM) model's residual stress prediction capability for its utility in developing friction stir processing (FSP). Specifically, two FSP tests under different processing conditions were conducted, and the corresponding simulations were carried out to verify if the TPM model can predict residual stresses for various tool radii and workpiece materials. The model was successful in predicting residual stresses for one of the tests but failed to work for the other test. Further simulations under different FSP conditions prove that the TPM model works for cast aluminum alloys in addition to wrought aluminum alloys. However, there is only a range of tool radii for which the TPM model is applicable, and the large FSP tool used is the reason for the model's failure on one of the tests. As a solution, this paper suggests modifications to the TPM model based on calibration to the FSP test temperatures. The calibrated TPM model still cannot predict the effect of the tool radii on the residual stresses; however, the effect on residual stresses due to changes in the process parameters, such as the tool traverse & rotation speeds and the clamping conditions, can be predicted.

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Section: Resultsmentioning

confidence: 99%

“…We propose to use an approach that has been suggested before but not expounded [40]. As a modification to the TPM model, a calibration parameter 𝜁𝜁 is added to the heat source.…”

Section: Modified Simulation Model For Fsp Test #2 41 Changes To the ...mentioning

confidence: 99%

On the Utility of the Thermal-Pseudo Mechanical Model’s Residual Stress Prediction Capability for the Development of Friction Stir Processing

Balusu

Choi

Das

et al. 2023

Int J Adv Manuf Technol

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show abstract

“…Furthermore, the mechanical loads entirely alter the residual distortion pattern from a saddle state to an anti-saddle state. A numerical model was created by Jin and Sandström [163] to analyze distributions of residual stress following the FSW of copper canisters. The model coupled elastoplasticity and heat transfer analyses.…”

Section: The Role Of the Residual Stressmentioning

confidence: 99%

A Review on Friction Stir Welding/Processing: Numerical Modeling

Akbari,

Asadi,

Sadowski

2023

Materials

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Friction stir welding (FSW) is a manufacturing process that many industries have adopted to join metals in a solid state, resulting in unique properties. However, studying aspects like temperature distribution, stress distribution, and material flow experimentally is challenging due to severe plastic deformation in the weld zone. Therefore, numerical methods are utilized to investigate these parameters and gain a better understanding of the FSW process. Numerical models are employed to simulate material flow, temperature distribution, and stress state during welding. This allows for the identification of potential defect-prone zones. This paper presents a comprehensive review of research activities and advancements in numerical analysis techniques specifically designed for friction stir welding, with a focus on their applicability to component manufacturing. The paper begins by examining various types of numerical methods and modeling techniques used in FSW analysis, including finite element analysis, computational fluid dynamics, and other simulation approaches. The advantages and limitations of each method are discussed, providing insights into their suitability for FSW simulations. Furthermore, the paper delves into the crucial variables that play a significant role in the numerical modeling of the FSW process.

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“…Even if the application of FSW to aluminum alloys has been widely investigated [2][3][4][5][6][7] and relevant issues have been clarified, for the effective employment of the technique to other engineering materials, in particular copper, several questions are still open. Indeed, despite the interesting and recently published reports [8][9][10][11][12][13][14][15][16][17][18][19][20], a systematic study is lacking. What is more, published results are often contrasting and a convergence of the scientific community on some issues, such as the characteristics of the different welding zones and relationship between welding parameters, recrystallization phenomena, and microhardness, seems quite far, as outlined in the following brief literature analysis.…”

Section: Introductionmentioning

confidence: 99%

The Influence of Pre-Heating on the Weldability of Pure Copper by FSW

Carlone¹,

Palazzo²

2014

TOMEJ

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This paper deals with an experimental investigation on the friction stir welding of pure copper. 4 mm thick copper plates have been welded in the butt joint configuration using a conical unthreaded tool, with and without\ud preheating. An electrically heated backing plate has been employed to increase the initial temperature of the plates and to investigate the influence of pre-heating on the weld ability of the considered material. The welded joints have been analyzed by means of macroscopic and microscopic observations, microhardness measurements and tensile tests. Obtained outcomes suggest that more complex pin shape is needed to promote an adequate material flow without pre-heating

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Numerical simulation of residual stresses for friction stir welds in copper canisters

Cited by 19 publications

References 12 publications

On the Utility of the Thermal-Pseudo Mechanical Model’s Residual Stress Prediction Capability for the Development of Friction Stir Processing

On the Utility of the Thermal-Pseudo Mechanical Model’s Residual Stress Prediction Capability for the Development of Friction Stir Processing

A Review on Friction Stir Welding/Processing: Numerical Modeling

The Influence of Pre-Heating on the Weldability of Pure Copper by FSW

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