Thermo-mechanical modelling of the Friction Stir Spot Welding process: Effect of the friction models on the heat generation mechanisms

Hannachi, Nasra; Khalfallah, Ali; Leitão, C.; Rodrigues, D.M.

doi:10.1177/14644207211070965

Cited by 5 publications

(4 citation statements)

References 37 publications

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“…Their findings revealed that the CEL modeling technique was not only more accurate, but also simpler to use and more computationally efficient in comparison to the ALE modeling technique. Hannachi and colleagues [129] examined and compared various friction models for their applicability in modeling the FSSW process of AA6082-T6 aluminum utilizing a CEL formulation. The models they investigated included the conventional Coulomb model, the modified Coulomb model, and the temperature-dependent friction coefficient-based model.…”

Section: Initial Statementioning

confidence: 99%

A Review on Friction Stir Welding: Numerical Modeling

Akbari¹,

Asadi²,

Sadowski³

2023

Preprint

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Employing numerical methods to simulate manufacturing processes and study their influential factors is increasing. The development of computers and engineering software has increased the ability and accuracy of numerical methods in simulating various aspects of different processes. One of the manufacturing processes that has been considered by many industries in recent years to join metals in solid-state with unique properties is called friction stir welding. It is challenging and, in some cases, impossible to experimentally study the various aspects of this process, such as temperature distribution, stress distribution, and material flow, due to severe plastic deformation in the weld zone. In this case, numerical methods are used to investigate these parameters and better understand the process. This study first investigates various numerical methods researchers use to simulate the process. The ability, pros, and cons of these methods to simulate the process are also examined. Then, the applications of numerical models in simulating the temperature distribution during the process as well as the effects of input parameters on the temperature history of the process, are deeply considered. Next, the application of numerical methods in material flow modeling during the process is investigated. Finally, the modeling of the microstructure of the welding zone is investigated using numerical methods that help significantly in predicting the weld microstructure.

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Section: Initial Statementioning

confidence: 99%

A Review on Friction Stir Welding: Numerical Modeling

Akbari¹,

Asadi²,

Sadowski³

2023

Preprint

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“…They discovered that the sample RS had higher temperatures and residual stresses than the sample AS, and they also discovered a strong correlation between simulation and experiment data. Hannachi et al [34] investigated different friction models in friction stir welding modeling and examined the advantages and disadvantages of each model. For this purpose, they developed a model using a CEL formulation.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the effect of welding and rotational speed on strain and temperature during friction stir welding of AA5083 and AA7075 using the CEL approach

Akbari

RahimiAsiabaraki

Aliha³

2023

Eng. Res. Express

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In this study, the friction stir welding between AA5083 and AA7075 is modeled using numerical methods, and the role of parameters affecting the process, such as welding speed and rotation speed on material flow, temperature, and strain, is studied. The temperature, strain, and material mixing were analyzed while welding AA7075 to AA5083 alloys using a Coupled Eulerian-Lagrangian (CEL) approach. It was discovered that the CEL approach had accurately anticipated the mixing of materials in the stir zone (SZ) by comparing the SZ of the samples fabricated experimentally and modeled by simulation. Results show that the temperature and strain increase dramatically as the rotation speed increases from 500 to 900 rev/min. The material flow obtained from the simulation shows that with increasing rotational speed or decreasing welding speed, AA7075 is more stretched towards AA5083 in the sheet's higher surfaces, indicating an increase in material flow intensity. Better material mixing and increased material flow allowed for the achievement of the maximum tensile strength at the welding and rotation speeds of 36 mm/min and 900 rev/min.

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“…The entire-process simulation strategy showed great potential for prediction and optimization of the macro- and micro-structural response of complex and large components. The effect of the friction model on heat generation during the FSSW process was investigated by Hannachi et al 12 They combined the sliding and sticking contact conditions for the heat generation mechanism while the plastic dissipated energy was the main source of heat generation and subsequently the determining factor in the evolution of temperature during the process. Even in this solid-state welding, however, there are some challenges with respect to the joining of aluminum to copper.…”

Section: Introductionmentioning

confidence: 99%

Advances in simulation and experimental study on intermetallic formation and thermomechanical evolution of Al–Cu composite with Zn interlayer: Effect of spot pass and shoulder diameter during the pinless friction stir spot welding process

Abdollah-zadeh

Bagheri

Vaneghi

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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In this study, the pinless friction stir spot welding of aluminum–copper composite with Zn interlayer was analyzed under experimental measurement and finite element method. The role of shoulder diameter, 16, 18, and 20 mm, and the number of spot pass, one to three pass, on microstructure, mechanical properties, and thermal history of weld samples were investigated. Based on the obtained results, there is a good agreement between numerical data and experimental analyses. It was shown that the heat source, due to plastic deformation and friction, increased as the shoulder diameter was increased, whereas the stress distribution in the weld samples was reduced. In addition, the thickness of the Zn interlayer at the joint interface changes when shoulder size increases from 16 to 20 mm, due to high temperature and intermixing between materials. From the microstructure analysis, the grain size in the joint zone gradually decreases as the spot pass increases from 1 to 3. It was concluded that the shoulder diameter of 16 mm with three spot passes showed the best result of 7.45 kN. Depending on X-ray diffraction analyses of the fracture surfaces, three primarily intermetallic phases including the Al2Cu, CuZn5, and CuZn2 were determined in the weld interfaces. Based on finite element method analysis, the axial compressive stresses showed the lowest profile as the shoulder diameter of the tool is 16 mm. Finally, the ductile fracture was detected as the main fracture mechanism for the joint sample with optimal joining conditions.

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Thermo-mechanical modelling of the Friction Stir Spot Welding process: Effect of the friction models on the heat generation mechanisms

Cited by 5 publications

References 37 publications

A Review on Friction Stir Welding: Numerical Modeling

A Review on Friction Stir Welding: Numerical Modeling

Investigation of the effect of welding and rotational speed on strain and temperature during friction stir welding of AA5083 and AA7075 using the CEL approach

Advances in simulation and experimental study on intermetallic formation and thermomechanical evolution of Al–Cu composite with Zn interlayer: Effect of spot pass and shoulder diameter during the pinless friction stir spot welding process

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