Heat transfer and metal flow behavior of AA7075 high-strength aluminum alloy in a new current-induced friction stir weld
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ORIGINAL ARTICLE
Heat transfer and metal flow behavior of AA7075 high-strength aluminum alloy in a new current-induced friction stir welding with a multi-physics field model based on the inverse method and parameter scanning batch processing technique J. Luo 1,2,3
&
J. F. Xiang 2,3 & L. Yuan 4 & H. X. Lin 5 & X. R. Wu 5 & D. Z. Xie 5
Received: 25 June 2020 / Accepted: 13 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract A new multi-physics field mathematical model is established to describe an advanced current-induced friction stir welding (CFSW) process. A reverse method and large-batch parameter scanning technique are used to analyze the influence of the axial force, welding rotational speed ratio, and current on the temperature field, flow field, residual strain, and stress field of CFSW. The thermal-force comprehensive effect of the additional current is studied in CFSW. The research results show that the hybrid current can achieve effective metallurgical bonding as a new current-induced friction stir welding mode, when the effective welding joint cannot be obtained due to insufficient heat input in traditional FSW. The high-temperature zone area of CFSW is larger than that of conventional FSW, and the hybrid current is helpful to reduce residual stress and strain. The additional current can increase the flow velocity of metal in welding seam, but it has little influence on the flow path and pattern of welding seam metal. More importantly, CFSW process allows higher welding speed and lower axial force owing to auxiliary resistance heat compared with traditional FSW, which makes CFSW able to achieve higher production efficiency and save tool cost. The threedimensional multi-physics field mathematical model of CFSW is reliable and correct in this paper. Keywords Current-induced friction stir welding . High-strength aluminum alloy . Reverse method . Large-batch parameter scanning technique . Current-induced effect . Heat transfer and metal flow behavior . Multi-physics field mathematical model
1 Introduction Friction stir welding (FSW) is a promising method of solidstate joining technology developed by TWI (The Welding Institute) [1]. FSW is designed primarily for the joining of
* J. Luo [email protected] 1
State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001, China
2
State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an 710072, China
3
State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing 400030, China
4
Beijing Special Vehicle Research Institute, Beijing 100072, China
5
College of Mechanical Engineering and Automation, Fuzhou University, Fuzhou 350116, China
aluminum alloy without the use of electrical arc. Currently, FSW is widely used in manufacturing the high-quality weld joint of difficult-to-weld alloy (such as Cu, Mg, and Ti alloys) [2–4]. More importantly, in recent years, FSW technology shows great advantage in joining dissimilar alloys such
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