Thermo-mechanical model with adaptive boundary conditions for friction stir welding of Al 6061

Soundararajan, V.; Zekovic, Srdja; Kovacevic, Radovan

doi:10.1016/j.ijmachtools.2005.02.008

Cited by 182 publications

(110 citation statements)

References 12 publications

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“…To avoid this convergence problem, the contact pairs were suppressed in the stress analysis, as the thermal stress accounts for the major part of the total stress built up during the FSW process [10], [13]. Moreover, this simplification does not impair the characteristics of the heat input source model used in the thermo-mechanical analysis.…”

Section: Stress Analysismentioning

confidence: 99%

“…Furthermore, most of the models assumed a constant convective coefficient on the whole surface. Only one recently work by Soundararajan et al, [10] used a contact pressure dependent heat transfer coefficient. An initial thermo-mechanical analysis with a uniform contact conductance value was performed to determine the stress at the workpiece-backing plate.…”

Section: An Adaptive Convective Boundary Condition Algorithmmentioning

confidence: 99%

“…Soundararajan et al, [10] refined the FE models in [8], [9] by applying an adaptive contact conductance at the interface of shoulder-workpiece. At the beginning of the FE thermo-mechanical analysis, a uniform contact conductance was used to predict the stress at the interface.…”

Section: Introductionmentioning

confidence: 99%

“…The above simplified models didn't include the contact pressure dependent heat transfer coefficient in their boundary condition definitions. Although Soundararajan et al, [10] considered this; the calculated non-uniform contact conductance at the beginning of the analayis was kept constant and used throughout the whole welding process.…”

Section: Introductionmentioning

confidence: 99%

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Simplified Thermo-Mechanical Modeling of Friction Stir Welding with a Sequential FE Method

Li¹,

Liu²

2014

IJMO

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Abstract-This paper presents a methodology for modeling the transient thermal and mechanical responses without computing the heat generated by friction or plastic deformation. The externally applied heat source accounts for the heat generated from tool movement. The novel heat source model includes two parts: surface heat flux at the shoulder-workpiece interface and nodal heat generation in the material that should have been displaced by the tool. The heat source algorithm is described through equations and flow charts. This thermal model was shown to predict a temperature history in good agreement with experimentally measured results. The mechanical interaction between the contacting surfaces was modelled with contact elements. However the analysis failed to converge with the contact pairs active. For the analysis without contact pairs, the predicted longitudinal direction stresses matched well with experiment but the transverse direction stresses were significantly different.Index Terms-Finite element analysis, friction stir welding, thermo-mechanical modeling, sequential method.

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Section: Stress Analysismentioning

confidence: 99%

Section: An Adaptive Convective Boundary Condition Algorithmmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Simplified Thermo-Mechanical Modeling of Friction Stir Welding with a Sequential FE Method

Li¹,

Liu²

2014

IJMO

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“…The results are then inputted into the structural FEA model in the form of thermal loads. The same approach has also been utilized in the past for example by Soundararajan et al [5], Staron et al [6] and Riahi et al [7] in order to analyze the thermo-structural behaviour of friction stir welded aluminium alloys.…”

Section: State Of the Art -Numerical Modellingmentioning

confidence: 99%

Simplified Thermo-Elastoplastic Numerical Modelling Techniques Applied to Friction Stir Welding of Mild Steel

Micallef

Camilleri

Mollicone

2013

Volume 2A: Advanced Manufacturing

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Friction stir welding is a relatively new advanced joining technique that requires minimal power input, ultimately leading to less inherent residual stresses and distortion. The process involves a spinning tool which first plunges into the surface of the, to be welded assembly and then traverses along the joint. Frictional heat is generated, softening the material at temperatures significantly below the melting temperature of the parent material. As the tool traverses along the joint at a predetermined speed, the assembly is joined by means of a plastic straining process. This advanced welding technology has been validated for various aluminium alloys but it is only recently, due to advances in tool technology, that the possibility of joining mild steel using friction stir welding has become a viable option. This study looks into friction stir welding of mild steel and develops simplified numerical methods for the prediction of thermal gradients, residual stresses and deformation. In principle the process modelling requires a multi-disciplinary approach involving coupled thermofluid, microstructural-structural modelling process. Much of the latest thermo-mechanical studies of friction stir welding rely on a number of over simplifications particularly related to the heat flux distribution across the tool shoulder, and also on the backing plate boundary conditions. The objective of this paper is to scrutinise the effects of modelling in more detail and establish the most important factors leading to accurate yet computationally efficient prediction of thermal gradients and inherent residual stresses. The results show that both the heat input and

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Thermal cycles and their effects during friction stir welding of AA7075 thicker plates with and without in‐process cooling

Rao

Selvaraj²,

Rao³

et al. 2021

Materialwissenschaft Werkst

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Friction stir welding of AA 7075 plates in three different thicknesses such as 10, 16 and 25 mm at natural convection condition was carried out successfully without defects. Water cooled friction stir welds were also produced on 16 mm thick plates. The thermal cycles at different locations of the plate, during the friction stir welding process, were predicted using a three-dimensional thermal model. Mechanical properties of the welds were evaluated using tensile and hardness tests. Weld microstructures were also examined with optical and transmission electron microscopes. The weld hardness values and tensile properties were found to decrease with increase in plate thickness. The use of water cooling was found to improve the weld properties to some extent, although not to the level of base metal. The reasons for this behavior are discussed, correlating thermal cycles, mechanical properties, fracture locations and precipitate morphology.

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Thermo-mechanical model with adaptive boundary conditions for friction stir welding of Al 6061

Cited by 182 publications

References 12 publications

Simplified Thermo-Mechanical Modeling of Friction Stir Welding with a Sequential FE Method

Simplified Thermo-Mechanical Modeling of Friction Stir Welding with a Sequential FE Method

Simplified Thermo-Elastoplastic Numerical Modelling Techniques Applied to Friction Stir Welding of Mild Steel

Thermal cycles and their effects during friction stir welding of AA7075 thicker plates with and without in‐process cooling

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