Recent advances in friction-stir welding : Process, weldment structure and properties

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Nonlinear Finite Elements For Continua And Structures

In this investigation an attempt has been made to understand the mechanism of friction stir weld formation and the role of friction stir welding tool in it. This has been done by understanding the material flow pattern in the weld produced in a special experiment, where the interaction of the friction stir welding tool with the base material is continuously increased. The results show that there are two different modes of material flow regimes involved in the friction stir weld formation; namely “pin-driven flow” and “shoulder-driven flow”. These material flow regimes merge together to form a defect-free weld. The etching contrast in these regimes gives rise to onion ring pattern in friction stir welds. In addition to that based on the material flow characteristics a mechanism of weld formation is proposed.

The role of friction stir welding tool on material flow and weld formation

https://cyberleninka.org/article/n/403409.pdf

A review of numerical analysis of friction stir welding

Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy

Numerical studies on controlling of process parameters in friction stir welding

3D modeling of material flow in friction stir welding under different process parameters

Solid mechanics-based finite element models and computational procedures are developed to study the flow patterns and the residual stresses in frictional stir welding (FSW). Two-dimensional results of the material flow patterns and the residual stresses are presented. The flow of metal during FSW is investigated using tracer particles. It is shown that the flows on the advancing side and retreating side are different. After several rotations the material which is rotating around the nib sloughs off in its wake of the pin, primarily on the advancing side. The residual stresses of the welded plate are investigated in this analysis. The distribution of the longitudinal residual stress along the direction perpendicular to the welding line is a double feature curve. With the increase of the translational velocity, the maximum longitudinal residual stress can be increased.

The finite element simulation of the friction stir welding process

A fully coupled thermo-mechanical finite element model was used to study the friction stir welding process of AA2024-T3 in different thicknesses. The computational results show that the material flows on the retreating and the front sides are higher. So, the slipping rates on the retreating and the front sides are lower than the ones on the trailing and advancing sides. This is the reason that the heat fluxes on the trailing and the advancing sides are higher, which leads to the fact that the temperatures are higher in this region for both thin and thick plates. The energy entering the welding plate accounts for over 50% in the total energy and about 85% in the energy comes from the frictional heat in FSW of AA2024-T3 and the balance from the mechanical effects. The stirring effect of the welding tool becomes weaker in FSW of thick plates. With consideration of the material deformations and the energy conversions, FSW of thin plates shows advantages.

Hongwu Zhang

Papers

Numerical studies on controlling of process parameters in friction stir welding

3D modeling of material flow in friction stir welding under different process parameters

The finite element simulation of the friction stir welding process

Coupled thermo-mechanical model based comparison of friction stir welding processes of AA2024-T3 in different thicknesses

Numerical Modeling of Friction Stir Welding Process by Using Rate-dependent Constitutive Model