Probing the Mechanism of Friction Stir Welding with ALE Based Finite Element Simulations and Its Application to Strength Prediction of Welded Aluminum

Myung, Dongjoon; Noh, Wooram; Kim, Jihoon; Kong, Juwon; Hong, Sung-Tae; Lee, Myoung‐Gyu

doi:10.1007/s12540-020-00901-8

Cited by 19 publications

(3 citation statements)

References 38 publications

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“…Computational solid mechanics (CSM) models. Within CSM, two principal methods have been employed: the arbitrary Lagrangian-Eulerian (ALE) [49][50][51][52][53][54][55][56][57][58][59][60][61][62] method, the coupled Eulerian-Lagrangian (CEL) approach , and the smoothed particle hydrodynamics (SPH) method.…”

Section: Process Modeling Techniquesmentioning

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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Section: Process Modeling Techniquesmentioning

confidence: 99%

A Review on Friction Stir Welding/Processing: Numerical Modeling

Akbari,

Asadi,

Sadowski

2023

Materials

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“…Therefore, unlike conventional welding, FSW is a solid-state welding technology that involves a highly complex thermomechanical-metallurgical process. [153,154] Owing to the characteristics of FSW, the friction stir welded part exhibits good weld quality, which can be maximized if the length of the welded part is secured, such as extruded aluminum. [155,156] Simar et al established an integrated modeling framework devoted to the FSW of 6xxx series Al alloys.…”

Section: Welding and Joiningmentioning

confidence: 99%

Integrated Computational Materials Engineering for Advanced Automotive Technology: With Focus on Life Cycle of Automotive Body Structure

Park

Min

Kim

et al. 2022

Adv Materials Technologies

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Integrated computational materials engineering (ICME) is a simulation‐driven design approach that employs multiscale‐multiphysics modeling and is based on the understanding of process–structure–property–performance relationships. The ICME approach has attracted considerable attention in the automotive industry, considering that it significantly reduces development cost and time in optimization of materials and processes through computational advancement. This study presents a comprehensive review of ICME activities in advanced automotive manufacturing technology, which focuses on the life cycle of the automotive body structure such as structural material design, manufacturing process optimization, and reliability improvement in service quality. Results show that the ICME approach has been widely implemented in automotive manufacturing processes, from development of lightweight materials to performance management. However, further advances and technological strategies should be sought to develop more robust methodologies that can replace conventional experiment‐based design approaches.

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“…1 Some of the advantages include lower residual stresses, low distortion, fewer weld defects and promising mechanical/fatigue performance compared to the conventional welding processes. 2 FSW is utilized in many industries to join aluminium, magnesium, copper and steel alloys in several configurations such as lap, butt, T. 3 High corrosion resistance, outstanding formability and weldability are amongst the most notable characteristics of aluminium alloy 5083 (AA5083). Thus, they are extensively utilized in trucks, pressure vessels, tanks, hulls, and shipbuilding structures.…”

Section: Introductionmentioning

confidence: 99%

Experimental studies on friction stir welding of aluminium alloy 5083 and prediction of temperature distribution using arbitrary Lagrangian–Eulerian-based finite element method

Pramod

Jain

Kumar³

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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The present work focused on welding aluminium alloy 5083 using the friction stir welding process. Suitable welding process parameters were identified to fabricate a defect-free butt joint with a tool rotational speed of 1600 rpm, traverse speed of 20 mm/min and tilt angle of 3°. The microstructure at the nugget zone, thermo mechanically affected zone, heat-affected zone and base metal zone are examined. Mechanical properties of the weldment exhibited promising results with an average joint efficiency and hardness of 75.70% and 94.0 ± 5.0 vickers hardness, respectively. Fractography revealed ductile mode of failure in base and weld metal tensile samples. Furthermore, a 3D thermomechanical finite element model was utilized to simulate the friction stir welding process using the selected process parameters. Arbitrary Lagrangian–Eulerian-based model aided in predicting residual stress distributions and thermal history during the friction stir welding process.

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Probing the Mechanism of Friction Stir Welding with ALE Based Finite Element Simulations and Its Application to Strength Prediction of Welded Aluminum

Cited by 19 publications

References 38 publications

A Review on Friction Stir Welding/Processing: Numerical Modeling

A Review on Friction Stir Welding/Processing: Numerical Modeling

Integrated Computational Materials Engineering for Advanced Automotive Technology: With Focus on Life Cycle of Automotive Body Structure

Experimental studies on friction stir welding of aluminium alloy 5083 and prediction of temperature distribution using arbitrary Lagrangian–Eulerian-based finite element method

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