Smoothed-Particle Hydrodynamics (SPH) Simulation of AA6061-AA5086 Dissimilar Friction Stir Welding

Aval, Hamed Jamshidi

doi:10.3390/met13050906

Metals

2023

DOI: 10.3390/met13050906

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Smoothed-Particle Hydrodynamics (SPH) Simulation of AA6061-AA5086 Dissimilar Friction Stir Welding

Hamed Jamshidi Aval

Abstract: The present study investigates thermo-mechanical issues associated with the dissimilar friction stir welding process of AA6061 and AA5086 aluminum alloys through smoothed-particle hydrodynamics (SPH) simulation and experimental investigations. The results demonstrate that the presented model accurately predicts the thermal history during the friction stir welding process. Furthermore, both simulation and experimental data indicate that when the AA6061 alloy is located on the advancing side, the temperature pro… Show more

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Cited by 4 publications

References 35 publications

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Post-processing ageing treatment of friction surfaced Al-16Si alloy: experimental and theoretical studies

Bararpour,

Jamshidi Aval,

Jamaati

et al. 2024

Materials Science and Technology

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In this study, we investigated the impact of ageing heat treatment following friction surfacing of a solid solution-treated Al-16Si alloy on coating geometry, microstructure, and wear resistance. We employed a simulation using the smoothed-particle hydrodynamics (SPH) method alongside experimental analysis. The simulation results revealed that as the rotational speed increased from 600 to 1000 rpm, the coating efficiency decreased significantly from 31.2 to 13.1%. When comparing the coating to the substrate and the consumable rod, it was seen that after ageing heat treatment, the wear rate of the coating made at a rotational speed of 600 rpm dropped by a lot, by 70% compared to the substrate and by 53% compared to the consumable rod.

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Post-processing ageing treatment of friction surfaced Al-16Si alloy: experimental and theoretical studies

Bararpour,

Jamshidi Aval,

Jamaati

et al. 2024

Materials Science and Technology

Self Cite

View full text Add to dashboard Cite

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Thermal Cycling, Microstructure, and Mechanical Properties of Al-Mg-Si-Cu Alloy Bobbin Tool Friction Stir Welded Joints Based on Thermal Index

Li,

Zhou,

Yin

et al. 2023

Coatings

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The two main process parameters of Bobbin tool friction stir welding (BT-FSW) are ω (rotational speed) and v (traverse speed). Both of these factors have a significant effect on heat input, microstructure, and mechanical properties. At present, most studies on friction stir welding adopt the control variable method to study the thermal cycling during the welding process and the mechanical properties of joints, and there are few studies on changing the two process parameters at the same time, because it can be difficult to assess the correlation between heat input and mechanical properties when changing both factors at the same time. In this study, the w/v ratio is defined as the thermal index, which is a characteristic value of heat input. The study uses ABAQUS 6.5 software to establish a BT-FSW CEL (coupled Eulerian–Lagrangian) thermal coupling model. This model explores the relationship between joint thermal cycles, microstructure, and mechanical properties for different w and v values with the same w/v ratio. The results show that increasing rotational and traverse speeds under the same w/v ratio leads to an increase in the peak temperature of the nugget zone (NZ). However, the peak temperature of the thermo-mechanically affected zone (TMAZ) and heat-affected zone (HAZ) remained almost constant. Joint strength was highest at a rotational speed of 750 r/min and a traverse speed of 650 mm/min, with a yield strength of 227 MPa. As rotational and traverse speeds increased, the recrystallized grain content of the NZ showed an increasing trend followed by a decreasing trend. The recrystallized grain content of the advancing side thermo-mechanically affected zone (AS-TMAZ) and retreating side thermo-mechanically affected zone (RS-TMAZ) showed a decreasing trend. Joint hardness had a “W” shaped distribution, with the highest average hardness value found in the NZ.

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Computational Modelling and Comparative Analysis of Friction Stir Welding and Stationary Shoulder Friction Stir Welding on AA6061

Marode,

Awang,

Janga

2023

Crystals

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This research focuses on the computational modelling and comparative analysis of friction stir welding (FSW) and stationary shoulder friction stir welding (SSFSW) applied to AA6061-T6 aluminium alloy. SSFSW, an FSW variant, employs a stationary shoulder and a rotating pin. This study introduces a numerical model for both processes, using the innovative Smoothed Particle Hydrodynamics (SPH) technique to capture their distinct thermo-mechanical characteristics. The aim is to unravel its mechanics and multi-physics in SSFSW and compare it with conventional FSW. The temperatures predicted by the model exhibited a close agreement between the advancing side (AS) and retreating side (RS). Plastic strain patterns show that regular FSW is different from SSFSW. In SSFSW, the strain is less, and the plastic area is comparatively slightly narrower. The distinct “ironing effect” resulting from the stationary shoulder in SSFSW reduces the heat-affected zone (HAZ). Yet, it maintains efficient plasticisation and material flow within the pin-affected zone (PAZ). This research emphasises the significant impact of temperature, strain, material flow, and thermo-mechanical characteristics on the quality of joints. Future suggestions include exploring process parameters more broadly, examining dissimilar welding techniques and hybrid approaches, and comprehensively investigating the diverse effects of SSFSW under various configurations and joint angles.

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Smoothed-Particle Hydrodynamics (SPH) Simulation of AA6061-AA5086 Dissimilar Friction Stir Welding

Cited by 4 publications

References 35 publications

Post-processing ageing treatment of friction surfaced Al-16Si alloy: experimental and theoretical studies

Post-processing ageing treatment of friction surfaced Al-16Si alloy: experimental and theoretical studies

Thermal Cycling, Microstructure, and Mechanical Properties of Al-Mg-Si-Cu Alloy Bobbin Tool Friction Stir Welded Joints Based on Thermal Index

Computational Modelling and Comparative Analysis of Friction Stir Welding and Stationary Shoulder Friction Stir Welding on AA6061

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