Three-dimensional heat and material flow during friction stir welding of mild steel

Nandan, R.; Roy, Gour Gopal; Lienert, Thomas J.; DebRoy, T.

doi:10.1016/j.actamat.2006.09.009

Cited by 535 publications

(355 citation statements)

References 31 publications

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“…Neto [19] and Schmidt and Hattel [20] documented that stick-sliding behaviour is more likely to occur in the FSW process and they argued that differences in the relative velocity at different angular locations on the tool surface will lead to some parts of the interface layer being under a stick condition and some parts will be in the partial slip regime.…”

Section: Stick Behaviourmentioning

confidence: 99%

“…Lower strain rates in this region are characteristic of a lack of stirring action for the worn tool, due to the conical shape, resulting in a narrow MAZ size that could cause improper flow and insufficient metal consolidation in this region [41]. It is also important to note that the rotating layers of the metal flow that form the weld zone strongly depends upon the tool geometry and process parameters [20,39]. As is shown in this study, a worn tool has a conical shape, which produces lower stirring action near the weld root with a reduction in the MAZ size.…”

Section: Predictions Of the Strain Rate Distributionmentioning

confidence: 99%

“…Nandan et al [20] and Arora et al [21] specified the velocity components on the tool surface in terms of the tool angular translation velocities; these components define the material velocity at the tool interface as shown in equations 4 and 5, which also included the δ term to specify the contact condition:…”

Section: Stick Behaviourmentioning

confidence: 99%

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A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries

2015

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The tool is a key component in the friction stir welding (FSW) process, but the tool degrades and changes shape during use, however, only a limited number of experimental studies have been undertaken in order to understand the effect that worn tool geometry has on the material flow and resultant weld quality. In this study, a validated model of the FSW process is generated using the CFD software FLUENT, with this model then being used to assess the detail of the differences in the flow behaviour, mechanically affected zone (MAZ) size and strain rate distribution around the tool for both unworn and worn tool geometries. Comparisons are made at two different tool rotational speeds using a single weld traverse speed. The study shows that there are significant differences in the flow behaviour around and under the tool when the tool is worn. This modelling approach can therefore be used to improve understanding of the effective limits of tool life for welding, with a specific outcome of being able to predict and interpret the behaviour when using specific weld parameters and component geometry without the need for experimental trials.

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Section: Stick Behaviourmentioning

confidence: 99%

Section: Predictions Of the Strain Rate Distributionmentioning

confidence: 99%

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A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries

2015

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“…In a FE model done by Nandan et al [107,108], a control volume method was used to discretize the FSW process. Temperature, cooling rate and plastic flow were predicted successfully by solving mass conservation, momentum and energy equations.…”

Section: Local Scalementioning

confidence: 99%

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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Friction Stir Welding (FSW) is a novel kind of welding for joining metals that are impossible or difficult to weld by conventional methods. Three-dimensional nature of FSW makes the experimental investigation more complex. Moreover, experimental observations are often costly and time consuming, and usually there is an inaccuracy in measuring the data during experimental tests. Thus, Finite Element Methods (FEMs) has been employed to overcome the complexity, to increase the accuracy and also to reduce costs. It should be noted that, due to the presence of large deformations of the material during FSW, strong distortions of mesh might be happened in the numerical simulation. Therefore, one of the most significant considerations during the process simulation is the selection of the best numerical approach. It must be mentioned that; the numerical approach selection determines the relationship between the finite grid (mesh) and deforming continuum of computing zones. Also, numerical approach determines the ability of the model to overcome large distortions of mesh and provides an accurate resolution of boundaries and interfaces. There are different descriptions for the algorithms of continuum mechanics include Lagrangian and Eulerian. Moreover, by combining the above-mentioned methods, an Arbitrary Lagrangian-Eulerian (ALE) approach is proposed. In this paper, a comparison between different numerical approaches for thermal analysis of FSW at both local and global scales is reviewed and the applications of each method in the FSW process is discussed in detail. Observations showed that, Lagrangian method is usually used for modelling thermal behavior in the whole structure area, while Eulerian approach is seldom employed for modelling of the thermal behavior, and it is usually employed for modelling the material flow. Additionally, for modelling of the heat affected zone, ALE approach is found to be as an appropriate approach. Finally, several significant challenges and subjects remain to be addressed about FSW thermal analysis and opportunities for the future work are proposed.

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“…The FSW tool is mainly composed of two parts, i.e., tool shoulder and tool pin. The tool shoulder contributes primarily to the heat generation during the welding [3][4][5]. Therefore, it is rather important to control the heat input from tool shoulder in order to reduce the negative effects of welding thermal cycles.…”

Section: Introductionmentioning

confidence: 99%

Improving the structure-property of aluminum alloy friction stir weld by using a non-shoulder-plunge welding tool

M(王敏)

Zhang

et al. 2016

Int J Adv Manuf Technol

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In order to improve the joint performances by controlling the thermal effect of tool shoulder, a non-shoulderplunge (NSP) welding tool is utilized to conduct friction stir welding (FSW) of an Al-Mg aluminum alloy in this paper. Sound FSW joint is successfully produced by using the NSP welding tool. In contrast to conventional FSW (C-FSW), the thermal effect of tool shoulder is effectively reduced by NSP-FSW, leading to a significant size reduction of shoulderaffected zone in the joint. Besides, the NSP-FSW joint shows finer grain structures in the stir zone and thermo-mechanically affected zone, and exhibits lower extents of grain coarsening, dislocation polygonization, and particle dissolution in the heat-affected zone. Hardness maps show that the softening region width of NSP-FSW joint is only nearly half that of C-FSW joint and the NSP-FSW joint exhibits higher hardness in the heat-affected zone than C-FSW joint. The tensile test results indicate that the joint efficiency is improved from 89 % of C-FSW joint to 97 % by the NSP-FSW process.

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Three-dimensional heat and material flow during friction stir welding of mild steel

Cited by 535 publications

References 31 publications

A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries

A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Improving the structure-property of aluminum alloy friction stir weld by using a non-shoulder-plunge welding tool

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