Thermal modeling of friction stir welding in a moving coordinate system and its validation

Song, MinYoung; Kovacevic, Radovan

doi:10.1016/s0890-6955(03)00022-1

Cited by 368 publications

(224 citation statements)

References 7 publications

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“…A thermal flow qº can be prescribed on a part of the boundary ∂Ω q , while the temperature θ º can be specified in the rest of the surface∂Ω θ. This can be written as: (10) Where ∂Ω = ∂Ω q ∪ ∂Ω θ and n is the unit outward normal to the boundary ∂Ω. The contribution qº is due to the cooling of the surfaces by convection and also by the heat transmission through the contact interfaces, e.g., the "tool-plates" and the "base-plates" interfaces.…”

Section: Thermal Modelmentioning

confidence: 99%

“…The model is based on the well known Rosenthal equation [8] which describes a quasi stationary temperature field over a semi-infinite plate due to a moving heat source. Kovacevic et al [9,10] carried out thermal and thermo-mechanical analyses using finite elements. These analyses are based on a heat source model, not considering the thermo-mechanical coupling generated by plastic flow.…”

Section: Introductionmentioning

confidence: 99%

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3D modeling of material flow and temperature in Friction Stir Welding

et al. 2009

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Section: Thermal Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

3D modeling of material flow and temperature in Friction Stir Welding

et al. 2009

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“…Comparing the velocity of the tool and the time required for the pieces to reach softening temperature, the optimal tool velocity has been provided by Chien et al (2005). The percentage of the generated heat from the tool shoulder or the tool pin was investigated by Song and Kovacevic (2003). The tool serves two primary functions: (a) heating of workpiece, and (b) movement of material to produce the joint.…”

Section: Introductionmentioning

confidence: 99%

Optimal FSW process parameters for aluminum alloys AA5083

Chien

Lin

Chen

2011

Journal of the Chinese Institute of Engineers

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Friction stir welding (FSW) can produce superior mechanical properties in the weld zone. The purpose of this article is to find the optimum FSW process operating conditions for two plates of aluminum alloy AA5083 welded in butt joint. In addition to optimizing the performance characteristics, the cost is considered in the optimal FSW process. In the FSW procedure, there are four major controllable four-level factors, i.e. the tool rotation speed, transverse speed (feed rate), tool tilt angle with respect to the workpiece surface, and pin tool length. The uncontrollable factors are the ultimate tensile strength and elongation rate which can be converted to signal-to-noise ratios the larger the better. In order to achieve the aim of robustness in the multiple response process, the gray-based Taguchi method is proposed. A gray relational grade obtained from gray relational analysis is used as the multiple performance characteristic. The resulting optimum process parameters are rotation speed at 1800 rpm, transverse speed at 180 mm/min, tool tilt angle at 1 , and pin tool length at 2.9 mm for the best multiple performance characteristics with minimum cost.

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“…Much modelling work has been carried out on the FSW process (e.g. [4][5][6][7][8][9][10][11][12]) and there have been a few models developed to predict the residual stresses generated. However there has been little, or no, modelling into the combined effects of welding stress development and mechanical tensioning.…”

Section: Introductionmentioning

confidence: 99%

FE Modelling of Mechanical Tensioning for Controlling Residual Stresses in Friction Stir Welds

Richards¹,

Prangnell²,

Withers³

et al. 2007

Thermec 2006

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SYNOPSISAlthough Friction Stir Welding (FSW) avoids many of the problems encountered when fusion welding high strength Al-alloys, it can still result in substantial residual stresses that have a detrimental impact on service life and induce distortion. An FE model has been developed to investigate the effectives of the mechanical tensioning technique for controlling residual stresses in FSWs. The model purely considered the heat input and the mechanical effects of the tool were ignored. Variables, such as tensioning level, heat input, and plate geometry, have been studied. Good general agreement was found between modelling results and residual stress measurements, justifying the assumption that the stress development is dominated by the thermal field. The results showed a progressive decrease in the residual stresses for increasing tensioning levels and, although affected by the heat input, a relatively low sensitivity to the welding variables. At tensioning levels greater than ~ 50% of the room temperature yield stress, tensile stresses were replaced by compressive residual stresses within the weld. Subsequently the modelling has been used to examine how mechanical tensioning can be applied in practical applications.

show abstract

Thermal modeling of friction stir welding in a moving coordinate system and its validation

Cited by 368 publications

References 7 publications

3D modeling of material flow and temperature in Friction Stir Welding

3D modeling of material flow and temperature in Friction Stir Welding

Optimal FSW process parameters for aluminum alloys AA5083

FE Modelling of Mechanical Tensioning for Controlling Residual Stresses in Friction Stir Welds

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