Parametric studies of dissimilar friction stir welding using computational fluid dynamics simulation

Velamati, Ratna Kishore; Arun, J.; Padmanabhan, R.; Balasubramanian, V.

doi:10.1007/s00170-015-6995-4

Cited by 21 publications

(5 citation statements)

References 23 publications

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“…This minimized obstacles to deformation under loading, decreasing the resistance to plastic deformation, resulting in lower hardness (Bauri et al, 2015). Under nonfavourable process parameters such as high TRS, larger SD and low TTS, more frictional heat is generated, causing grain coarsening (Padmanaban et al, 2014;Behnagh et al, 2016;Kishore et al, 2015). This may lead to lower hardness as observed in the specimens FSP02, FSP08 and FSP18.…”

Section: Hardnessmentioning

confidence: 99%

Microstructure, hardness and corrosion behaviour of friction-stir processed AA5083

Ramalingam

Padmanaban

Datta

2019

ACMM

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Purpose The purpose of this study is to refine the microstructure and improve the corrosion behaviour of aluminium alloy AA5083 by subjecting it to friction stir processing (FSP). Design/methodology/approach FSP trials are conducted as per central composite design, by varying tool rotation speed, tool traverse speed and shoulder diameter at three levels. The microstructure is examined and the hardness is measured for both the base material and the processed workpieces. The corrosion behaviour of the base material and processed workpieces is studied using potentiodynamic polarization technique for three different testing temperatures, and the corrosion current and corrosion rate are calculated. Findings The results reveal that FSP refined the grains, dispersed secondary phases, increased the hardness and improved the corrosion resistance of most of the friction stir processed specimens than the base material at all the three testing temperatures. Grain refinement and fine dispersion of ß phase improves the hardness and corrosion resistance of most of the FSPed specimens. However partial dissolution of ß phase decreases the hardness in some of the specimens. Most of the FSPed specimens displayed more positive potential than the base material at all the testing temperatures representing a higher nobility than the base material, as a result of fine dispersion of secondary phase particles in the matrix. Large pits formed on the surface of the base specimen indicating a higher corrosion rate at all three testing temperatures. The SEM image of FSPed specimens reveals the occurrence of very few pits and minimal corrosion products on the surface, which indicates lower corrosion rate. Originality/value The corrosion mechanism of the friction stir-processed AA5083 specimens is found to be a combination of activation and concentration polarization.

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Section: Hardnessmentioning

confidence: 99%

Microstructure, hardness and corrosion behaviour of friction-stir processed AA5083

Ramalingam

Padmanaban

Datta

2019

ACMM

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“…Since recent publications do not give definitive direction as to the optimal weld configuration (i.e., the placement of the alloy on the retreating or advancing side), the examined joints were produced in two configurations. Some researchers [10,14,28,29] reported that when the weaker alloy is placed on the retreating side, the produced weld becomes weaker compared to the opposite configuration. However, according to other investigations [12,13,30], the more efficient mixing of materials and better properties can be achieved with the softer alloy on the advancing side and the harder alloy on the retreating side.…”

Section: Effect Of Alloy Configurationmentioning

confidence: 99%

Effect of process parameters on mechanical properties of friction stir welded dissimilar 7075-T651 and 5083-H111 aluminum alloys

Kalemba–Rec

Kopyściański

Miara

et al. 2018

Int J Adv Manuf Technol

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In this paper, the influence of process parameters (tool rotational speed, pin design, and configuration of joined alloys) on the macrostructure and mechanical properties of friction stir welded aluminum alloys 7075-T651 and 5083-H111 was characterized. The tool rotational speed and the alloy placement significantly influenced the formation of the weld (especially the stir zone). Superior mixing of materials was obtained at higher rotational speeds and in the configuration with 5083 on the advancing side and 7075 on the retreating side. However, under these conditions, more defects, such as porosity, voids, or wormholes, were found in the stir zone. Regardless of the pin design and weld configuration, with an increasing tool rotational speed, the mechanical properties decrease. Using the Triflute pin, however, guarantees higher tensile strength and weld efficiency (above 100%). The weld configuration did not influence the mechanical properties. The highest tensile strength (371 MPa) defect-free joint was obtained with 5083 on the advancing side, 7075 on the retreating side, a tool rotational speed of 280 rpm, and the Triflute pin.

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“…Through microstructure welding was shown to be more stable than other operating conditions when done at a feed speed of 30 mm/min and tool speed of 3000 rpm [26]. Various studies have observed the welding of various types of Aluminium and Steel alloys using the FSW process [1,4,5,13]. However, there is no report on the numerical simulation of dissimilar FCW of Al 6061-T6 alloy and Stainless Steel 304 alloy.…”

Section: Fig 1 Friction Crush Welding Schematic Drawingmentioning

confidence: 99%

“…Material location on the approaching and receding sides affects mixing efficiency. AA5082 has better mixing properties than AA6061 when placed on advancing side [13]. Liu et al (2016) studied the FSW of the alloy of Aluminium Al6061 and TRIP Steel based of the Eulerian formulation, a linked thermal-mechanical model was developed.…”

Section: Introductionmentioning

confidence: 99%

“…With rising tool speed and shoulder diameter, the temperature on the plates that are welded rises, and it falls with increasing welding speed [12]. Kishore et al (2015) examined a 2-D stable-state visco plastic model with various metals. By altering the location of the tool, material and process parameter profiles, the AA5083 and AA6061; and AA2024 and AA7075 were produced, verified, and analysed for variation of temperature and material flow.…”

Section: Introductionmentioning

confidence: 99%

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Friction Crush Welding of Dissimilar Materials: Numerical Modelling and Experimental Investigation

Kumar,

Brar,

Singh

2023

Preprint

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Several present day applications require joining of dissimilar materials by solid state processes. In this research work, two dissimilar metals – Aluminium and Steel were joined with a newly developed Friction Crush Welding (FCW) process. Macro-structure images along with X-Ray Diffraction (XRD) pattern were used to investigate the prepared samples. This work also aims to develop a novel Finite Element (FE) model based on ABAQUS for FCW of Aluminium-Steel materials. The numerical model was developed as a three-dimensional, explicit non-linear model utilising the Lagrange technique in ABAQUS. The developed FE model was validated by comparing the simulation results with experimental temperature data obtained by infrared thermography. The predicted temperature values from FE model are in excellent agreement with the experimentally measured values. The influence of welding variables, i.e., tool rotational speed (2000, 3000 and 4000 rpm) and welding speed (15, 30 and 45 mm/min) on temperature was also investigated. Results show that best weld structure is obtained when welding is performed at speed of 30 mm/min and tool rotational speed of 3000 rpm. The developed FE model of the FCW process may be used for predicting the temperatures and predicting the weld structure.

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Parametric studies of dissimilar friction stir welding using computational fluid dynamics simulation

Cited by 21 publications

References 23 publications

Microstructure, hardness and corrosion behaviour of friction-stir processed AA5083

Microstructure, hardness and corrosion behaviour of friction-stir processed AA5083

Effect of process parameters on mechanical properties of friction stir welded dissimilar 7075-T651 and 5083-H111 aluminum alloys

Friction Crush Welding of Dissimilar Materials: Numerical Modelling and Experimental Investigation

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