An advanced modelling to improve the prediction of thermal distribution in friction stir welding (FSW) for difficult to
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(2021) 43:4
TECHNICAL PAPER
An advanced modelling to improve the prediction of thermal distribution in friction stir welding (FSW) for difficult to weld materials Yasin Sarikavak1 Received: 31 March 2020 / Accepted: 16 November 2020 © The Brazilian Society of Mechanical Sciences and Engineering 2020
Abstract This study explores the thermal distribution of high-strength engineering alloys during the friction stir welding process (FSW). Materials which are difficult to weld or are unweldable by conventional welding processes can be successfully welded by FSW. The specific analysis and modification of the process require an understanding of the actual mechanism of the process. Therefore, a transient, three-dimensional, thermo-mechanical finite element model (FEM) for FSW was developed. The model calculates the temperature distribution during the welding process considering various boundary conditions such as rotational speed, linear speed, normal pressure, tool diameter and material properties. The thermo-mechanical FEM calculations consider the effects of conduction and convection heat transfer. The numerical results are successfully compared and validated by experimental results published in the literature for aluminium alloy, titanium alloy and steel (mild and bainitic) as workpiece materials. The model was found to be useful for understanding the effects of changes in different system parameters, and for selecting the optimum welding conditions before undertaking high-cost physical testing. Keywords Friction stir welding · Finite element model · Transient thermal model · Heat generation · Temperature distribution
1 Introduction Friction stir welding (FSW) is a relatively new method which has some advantages over conventional friction welding as well as other welding techniques. The method was invented in The Welding Institute (TWI) in 1991 for joining aluminium alloys which are difficult to weld with conventional methods. Primarily, FSW is applicable for joining low melting point materials such as aluminium alloys, copper and magnesium. The effects of the process parameters on the microstructure [1–3], thermal and mechanical properties of aluminium alloys [4–7] have been studied by several researchers. The feasibility of joining copper and dissimilar materials such as aluminium and copper has also been studied to investigate the optimum machining parameters on Technical Editor: Izabel Fernanda Machado. * Yasin Sarikavak [email protected]; [email protected] 1
Mechanical Engineering Department, Faculty of Engineering and Natural Sciences, Ankara Yıldırım Beyazıt University, 06010 Ankara, Turkey
the mechanical properties of the materials [8, 9]. Recently, several research and development studies have been conducting to explore the potential applications of FSW for harder materials such as steel and titanium alloys [10–17]. The tools used in FSW consist of elements such as shoulder and pin. The shoulder is the material which generates heat, prevents material removal and assists material movement aroun
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