Prediction of temperature and residual stress distributions in friction stir welding of aluminum alloy

Nie, Lin; Wu, Yanqing; Gong, Hai

doi:10.1007/s00170-019-04826-4

Cited by 32 publications

(11 citation statements)

References 28 publications

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“…The results of heating are quite similar to Liu et al (2022) [ 29 ] and Nie et al (2020) [ 30 ] for aluminum, which showed the reliability of our conclusions.…”

Section: Resultssupporting

confidence: 92%

Optimization of Bead Geometry during Tungsten Inert Gas Welding Using Grey Relational and Finite Element Analysis

Hanif

Shah

et al. 2023

Materials

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Mild steel welded products are widely used for their excellent ductility. Tungsten inert gas (TIG) welding is a high-quality, pollution-free welding process suitable for a base part thickness greater than 3 mm. Fabricating mild steel products with an optimized welding process, material properties, and parameters is important to achieve better weld quality and minimum stresses/distortion. This study uses the finite element method to analyze the temperature and thermal stress fields during TIG welding for optimum bead geometry. The bead geometry was optimized using grey relational analysis by considering the flow rate, welding current, and gap distance. The welding current was the most influential factor affecting the performance measures, followed by the gas flow rate. The effect of welding parameters, such as welding voltage, efficiency, and speed on the temperature field and thermal stress were also numerically investigated. The maximum temperature and thermal stress induced in the weld part were 2083.63 °C and 424 MPa, respectively, for the given heat flux of 0.62 × 106 W/m2. Results showed that the temperature increases with the voltage and efficiency of the weld joint but decreases with an increase in welding speed.

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“…The results of heating are quite similar to Liu et al (2022) [ 29 ] and Nie et al (2020) [ 30 ] for aluminum, which showed the reliability of our conclusions.…”

Section: Resultssupporting

confidence: 92%

Optimization of Bead Geometry during Tungsten Inert Gas Welding Using Grey Relational and Finite Element Analysis

Hanif

Shah

et al. 2023

Materials

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“…defective or sound joint, is strongly influenced by the temperatures reached in the hot zone around the tool [3]. Also, the final microstructure in the various areas that make up the joint and the consequent mechanical properties [4], as well as any residual stress [5] that may be found in the welded plates, are other components driven by the thermal history of the material, understood as the maximum temperatures reached and the severity of the thermal cycles (time spent at certain temperatures by the base material). In addition, peak temperature evolution with process parameters is essential for recent temperature control applications in FSW [6].…”

Section: Introductionmentioning

confidence: 99%

A semi-empirical model for peak temperature estimation in friction stir welding of aluminium alloys

Ambrosio

Aldanondo

Wagner

et al. 2022

Science and Technology of Welding and Joining

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Process parameters and base material thermal properties strongly affect peak temperature evolution in friction stir welding (FSW). This work develops a semi-empirical model for peak temperature estimation during FSW of aluminium alloys. Several bead-on-plate runs were conducted on AA5083-H111, AA6082-T6 and AA7075-T6. Different rotational and welding speeds were tested while measuring the temperature with a thermocouple embedded in the tool. A polynomial model was proposed with the model's coefficients strongly correlating to the material thermal properties. Additionally, a threshold peak temperature was defined to avoid cold defects by combining temperature measurements with joint quality information obtained from X-ray scans. The efficiency of the model and the defined threshold are proven by applying them to the literature.

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“…These superior properties are responsible for their wide application in the fabrication of aircraft wings and fuselages, automotive rims, and wheel spacers [4,5]. However, it is a huge challenge for improving the manufacturing industry to realize high-quality and efficient aluminum alloy ultrathin plate connections [6][7][8]. Therefore, advanced Laser Beam Welding (LBW) technology and Metal Inert-gas Welding (MIG) were adopted to weld 1 mm 3-Series Al alloy plates.…”

Section: Introductionmentioning

confidence: 99%

Effect of High Rotational-Speed Friction-Stir Welding on Microstructure and Properties of Welded Joints of 6061-T6 Al Alloy Ultrathin Plate

et al. 2021

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The butt joint of an Al alloy ultrathin plate with a thickness of 0.5 mm is realized by a high rotational-speed friction-stir welding process. It overcomes the welding difficulty that the ultrathin plate is often torn, and it cannot be formed by conventional friction-stir welding. The results show that the weld surface is well-formed at a high-rotational speed (more than 8000 rpm), and there are no obvious defects in each area of the joint section. The nugget zone (NZ) is a recovery recrystallization structure dominated by large-angle grain boundaries, with a grain size of about 4.9 μm. During grain growth, the texture is randomly and uniformly distributed, and the strength is balanced. The microhardness of the NZ increases significantly with the increase in rotational speed, and the fluctuation range of hardness value is small. The NZ β–Mg2Si is finer and significantly less than the base metal (BM). The heat dissipation of the thin plate is fast, so a Cu plate is used as the backing plate to slow down the steep temperature-drop process in the weld area. Compared with a low rotational speed, the precipitation amount of brittle phase Al–Cu–Mg–Cr and Al–Fe–Si–Mn is significantly reduced, which is conducive to improving the mechanical properties of the joint. At a high rotational speed, 12,000 rpm, the best tensile strength of the joint is 220 MPa, which is about 76% of the BM (290 MPa), and the highest elongation is 9.3%, which is about 77.5% of the BM (12%). The fracture mode of the joint is a typical plastic fracture.

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Prediction of temperature and residual stress distributions in friction stir welding of aluminum alloy

Cited by 32 publications

References 28 publications

Optimization of Bead Geometry during Tungsten Inert Gas Welding Using Grey Relational and Finite Element Analysis

Optimization of Bead Geometry during Tungsten Inert Gas Welding Using Grey Relational and Finite Element Analysis

A semi-empirical model for peak temperature estimation in friction stir welding of aluminium alloys

Effect of High Rotational-Speed Friction-Stir Welding on Microstructure and Properties of Welded Joints of 6061-T6 Al Alloy Ultrathin Plate

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