Pin Angle Thermal Effects on Friction Stir Welding of AA5058 Aluminum Alloy: CFD Simulation and Experimental Validation

Chupradit, Supat; Suksatan, Wanich; Landowski, Marcel; Fydrych, Dariusz; Abdullah, Mahmoud E.; Derazkola, Hesamoddin Aghajani

doi:10.3390/ma14247565

Cited by 24 publications

(18 citation statements)

References 67 publications

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“…FSSW tools made from tungsten carbide (WC) with a cylindrical probe (length: 0.9 mm, diameter: 8.2 mm) and shoulder diameter of 20 mm were used. There are many design considerations for manufacturing of FSW and FSSW tools [43][44][45]. However, the tool material was selected based on the tool material required for welding high-melting-point materials, as the work deals with both steel and copper alloys.…”

Section: Friction Stir Spot Welding (Fssw)mentioning

confidence: 99%

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

et al. 2022

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In the current study, a 2 mm thick low-carbon steel sheet (A283M—Grade C) was joined with a brass sheet (CuZn40) of 1 mm thickness using friction stir spot welding (FSSW). Different welding parameters including rotational speeds of 1000, 1250, and 1500 rpm, and dwell times of 5, 10, 20, and 30 s were applied to explore the effective range of parameters to have FSSW joints with high load-carrying capacity. The joint quality of the friction stir spot-welded (FSSWed) dissimilar materials was evaluated via visual examination, tensile lap shear test, hardness test, and macro- and microstructural investigation using SEM. Moreover, EDS analysis was applied to examine the mixing at the interfaces of the dissimilar materials. Heat input calculation for the FSSW of steel–brass was found to be linearly proportional with the number of revolutions per spot joint, with maximum heat input obtained of 11 kJ at the number of revolutions of 500. The temperature measurement during FSSW showed agreement with the heat input dependence on the number of revolution. However, at the same revolutions of 500, it was found that the higher rotation speed of 1500 rpm resulted in higher temperature of 583 °C compared to 535 °C at rotation speed of 1000 rpm. This implies the significant effect for the rotation speed in the increase of temperature. The macro investigations of the friction stir spot-welded joints transverse sections showed sound joints at the different investigated parameters with significant joint ligament between the steel and brass. FSSW of steel/brass joints with a number of revolutions ranging between 250 to 500 revolutions per spot at appropriate tool speed range (1000–1500 rpm) produces joints with high load-carrying capacity from 4 kN to 7.5 kN. The hardness showed an increase in the carbon steel (lower sheet) with maximum of 248 HV and an increase of brass hardness at mixed interface between brass and steel with significant reduction in the stir zone hardness. Microstructural investigation of the joint zone showed mechanical mixing between steel and brass with the steel extruded from the lower sheet into the upper brass sheet.

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Section: Friction Stir Spot Welding (Fssw)mentioning

confidence: 99%

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

et al. 2022

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“…Achieving the capacity of the above theory is a goal of researchers that requires easy passage of oxygen and proper conduction of electrons and ions with no blockage of cavities [192][193][194][195]. It has been found that a suitable geometric structure with two pore dimensions, one with large dimensions for the passage of oxygen gas and the other with small mesoporous cavities, provides a suitable result for the reaction and placement of lithium oxide [191,196,197].…”

Section: Graphene Is Engineered In Cathode Fabricationmentioning

confidence: 99%

A Review of High-Energy Density Lithium-Air Battery Technology: Investigating the Effect of Oxides and Nanocatalysts

Suryatna

Raya

Thangavelu

et al. 2022

Journal of Chemistry

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In vehicles that require a lot of electricity, such as electric vehicles, it is necessary to use high-energy batteries. Among the developed batteries, the lithium-ion battery has shown better performance. This battery has an energy density of 10 equal to that of a lithium-ion battery and uses air oxygen as the active material of the cathode and anode like a lithium-ion battery made of lithium metal. The cathode used in these batteries must have special properties such as strong catalytic activity and high conductivity, and nanotechnology has greatly helped to improve the materials used in the cathode of lithium-air batteries. The importance of proper catalyst distribution and the relationship between the oxide product and the catalyst and the indirect effect of the ORR catalyst on the OER reaction is not present in the fuel cell. The maximum capacity of lithium-air battery theory using graphene under optimal electron conduction conditions and the experimental maximum obtained for graphene by optimizing the structure geometry, examples of structural engineering using carbon fiber and carbon nanotubes in cathode fabrication with the ability to perform the reaction properly while providing space for lithium oxide placement, are examined. This article describes the mechanism of this battery, and its components are examined. The challenges of using this battery and the application of nanotechnology to solve these challenges are also discussed.

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“…where, A r is any small area on the tool-BM interfaces, r is the radial distance of the center of the area from the tool axis, V is the control-volume enclosing the area A r , τ is the BM shear stress and θ is the angle with the negative x-axis in the counter-clockwise direction, η is defined as the mechanical efficiency, δ denotes the spatially variable fractional slip between the tool and the BM interface, µ f is the friction coefficient, ω is the rotational velocity, and P N is the axial pressure. The generated heat by plastic deformation (Q p ), can be calculated as [60]:…”

Section: Boundary Conditionsmentioning

confidence: 99%

Effect of Pin Shape on Thermal History of Aluminum-Steel Friction Stir Welded Joint: Computational Fluid Dynamic Modeling and Validation

et al. 2021

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This article studied the effects of pin angle on heat generation and temperature distribution during friction stir welding (FSW) of AA1100 aluminum alloy and St-14 low carbon steel. A validated computational fluid dynamics (CFD) model was implemented to simulate the FSW process. Scanning electron microscopy (SEM) was employed in order to investigate internal materials’ flow. Simulation results revealed that the mechanical work on the joint line increased with the pin angle and larger stir zone forms. The simulation results show that in the angled pin tool, more than 26% of the total heat is produced by the pin. Meanwhile, in other cases, the total heat produced by the pin was near 15% of the total generated heat. The thermo-mechanical cycle in the steel zone increased, and consequently, mechanical interlock between base metals increased. The simulation output demonstrated that the frictional heat generation with a tool without a pin angle is higher than an angled pin. The calculation result also shows that the maximum heat was generated on the steel side.

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Pin Angle Thermal Effects on Friction Stir Welding of AA5058 Aluminum Alloy: CFD Simulation and Experimental Validation

Cited by 24 publications

References 67 publications

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

A Review of High-Energy Density Lithium-Air Battery Technology: Investigating the Effect of Oxides and Nanocatalysts

Effect of Pin Shape on Thermal History of Aluminum-Steel Friction Stir Welded Joint: Computational Fluid Dynamic Modeling and Validation

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