Prediction of temperature distribution and thermal history during friction stir welding: input torque based model

Khandkar, Mir Zahedul H.; Khan, Jamil A.; Reynolds, Anthony P.

doi:10.1179/136217103225010943

Cited by 298 publications

(200 citation statements)

References 5 publications

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“…Hamilton et al [93] and Khandkar et al [92] employed a torque base heat input parameter to find the maximum welding temperature for 304L stainless steel and various aluminum alloys. Energy-slip factor was established in a thermal model to find the relationship between the energy per unit length and the solidus temperature.…”

Section: Lagrangian Eulerian Methodsmentioning

confidence: 99%

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A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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Friction Stir Welding (FSW) is a novel kind of welding for joining metals that are impossible or difficult to weld by conventional methods. Three-dimensional nature of FSW makes the experimental investigation more complex. Moreover, experimental observations are often costly and time consuming, and usually there is an inaccuracy in measuring the data during experimental tests. Thus, Finite Element Methods (FEMs) has been employed to overcome the complexity, to increase the accuracy and also to reduce costs. It should be noted that, due to the presence of large deformations of the material during FSW, strong distortions of mesh might be happened in the numerical simulation. Therefore, one of the most significant considerations during the process simulation is the selection of the best numerical approach. It must be mentioned that; the numerical approach selection determines the relationship between the finite grid (mesh) and deforming continuum of computing zones. Also, numerical approach determines the ability of the model to overcome large distortions of mesh and provides an accurate resolution of boundaries and interfaces. There are different descriptions for the algorithms of continuum mechanics include Lagrangian and Eulerian. Moreover, by combining the above-mentioned methods, an Arbitrary Lagrangian-Eulerian (ALE) approach is proposed. In this paper, a comparison between different numerical approaches for thermal analysis of FSW at both local and global scales is reviewed and the applications of each method in the FSW process is discussed in detail. Observations showed that, Lagrangian method is usually used for modelling thermal behavior in the whole structure area, while Eulerian approach is seldom employed for modelling of the thermal behavior, and it is usually employed for modelling the material flow. Additionally, for modelling of the heat affected zone, ALE approach is found to be as an appropriate approach. Finally, several significant challenges and subjects remain to be addressed about FSW thermal analysis and opportunities for the future work are proposed.

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Section: Lagrangian Eulerian Methodsmentioning

confidence: 99%

“…To study the temperature profile, a three dimensional model was used by Khandkar et al [92]. In their research, experimental observations were used to measure the generated heat and the torque amount for butt welds.…”

Section: Lagrangian Eulerian Methodsmentioning

confidence: 99%

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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“…In this case, a self-limiting system is achieved, where the material at the tool-workpiece interface transfers from a stick-to-slip phase as the T S is reached, decreasing the heat generation due to the reduction on friction [2,3,10]. The weld temperature to achieve sound welds has been reported just below the T S measured in centigrade, in the range of 80 % T S [6], 60-90 % T S [2] or 80-90 % T S [4].…”

Section: Introductionmentioning

confidence: 99%

“…The weld temperature distribution as well as the material flow during welding determine the defect development, microstructure evolution and, consequently, the resulting joint's mechanical properties. The weld parameters, material thickness, the alloy to be welded and the tool design strongly affect the weld temperature [2,3,5], and the backing bar material has also been reported to have an influence [5,6]. The implementation of temperature control for FSW allows optimisation of the process and is in some applications essential to obtain sound welds [2][3][4][5]7].…”

Section: Introductionmentioning

confidence: 99%

Temperature measurements during friction stir welding

Silva

Backer

Bolmsjö

2016

Int J Adv Manuf Technol

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The increasing industrial demand for lighter, more complex and multi-material components supports the development of novel joining processes with increased automation and process control. Friction stir welding (FSW) is such a process and has seen a fast development in several industries. This welding technique gives the opportunity of automation and online feedback control, allowing automatic adaptation to environmental and geometrical variations of the component. Weld temperature is related to the weld quality and therefore proposed to be used for feedback control. For this purpose, accurate temperature measurements are required. This paper presents an overview of temperature measurement methods applied to the FSW process. Three methods were evaluated in this work: thermocouples embedded in the tool, thermocouples embedded in the workpiece and the tool-workpiece thermocouple (TWT) method. The results show that TWT is an accurate and fast method suitable for feedback control of FSW.

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“…The value of heat transfer coefficient (h) around the tool has been increased to compensate the effect of radiation [25].…”

Section: C-heat Losses From Workpiece Surfaces (Top and Sides)mentioning

confidence: 99%

Thermo-Mechanical Effect on Poly Crystalline Boron Nitride Tool Life During Friction Stir Welding (Dwell Period)

Al-moussawi

Smith

2018

Met. Mater. Int.

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Poly Crystalline Boron Nitride (PCBN) tool wear during the friction stir welding of high melting alloys is an obstacle to commercialize the process. This work simulates the friction stir welding process and tool wear during the plunge/dwell period of 14.8 mm EH46 thick plate steel. The Computational Fluid Dynamic (CFD) model was used for simulation and the wear of the tool is estimated from temperatures and shear stress profile on the tool surface. Two sets of tool rotational speeds were applied including 120 and 200 RPM. Seven plunge/dwell samples were prepared using PCBN FSW tool, six thermocouples were also embedded around each plunge/dwell case in order to record the temperatures during the welding process. Infinite focus microscopy technique was used to create macrographs for each case. The CFD result has been shown that a shear layer around the tool shoulder and probe-side denoted as thermo-mechanical affected zone (TMAZ) was formed and its size increase with tool rotational speed increase. Maximum peak temperature was also found to increase with tool rotational speed increase. PCBN tool wear under shoulder was found to increase with tool rotational speed increase as a result of tool's binder softening after reaching to a peak temperature exceeds 1250 °C. Tool wear also found to increase at probe-side bottom as a result of high shear stress associated with the decrease in the tool rotational speed. The amount of BN particles revealed by SEM in the TMAZ were compared with the CFD model.

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Prediction of temperature distribution and thermal history during friction stir welding: input torque based model

Cited by 298 publications

References 5 publications

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Temperature measurements during friction stir welding

Thermo-Mechanical Effect on Poly Crystalline Boron Nitride Tool Life During Friction Stir Welding (Dwell Period)

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