THERMAL SCIENCE

International Scientific Journal

Darko M. Veljić

,

Aleksandar S. Sedmak

,

Marko P. Rakin

,

Nikola S. Bajić

,

Bojan I. Medjo

,

Darko R. Bajić

,

Vencislav K. Grabulov

EXPERIMENTAL AND NUMERICAL THERMO-MECHANICAL ANALYSIS OF FRICTION STIR WELDING OF HIGH-STRENGTH ALLUMINIUM ALLOY

ABSTRACT
This paper presents experimental and numerical analysis of the change of temperature and force in the vertical direction during the friction stir welding of high-strength aluminium alloy 2024 T3. This procedure confirmed the correctness of the numerical model, which is subsequently used for analysis of the temperature field in the welding zone, where it is different to determine the temperature experimentally. 3D finite element model is developed using the software package Abaqus; arbitrary Lagrangian-Eulerian formulation is applied. Johnson-Cook material law and Coulomb’s Law of friction are used for modelling the material behaviour. Temperature fields are symmetrical with respect to the welding line. The temperature values below the tool shoulder, i.e. in the welding zone, which are reached during the plunge stage, are approximately constant during the entire welding process and lie within the interval 430-502°C. The temperature of the material in the vicinity of the tool is about 500°C, while the values on the top surface of the welding plates (outside the welding zone, but close to the tool shoulder) are about 400°C. The temperature difference between the top and bottom surface of the plates is small, 10-15°C. [Projekat Ministarstva nauke Republike Srbije, br. TR 34018 and ON 174004]
KEYWORDS
friction stir welding, aluminium alloys, finite element analysis, temperature fields, thermo-vision measurement
PAPER SUBMITTED: 2013-05-12
PAPER REVISED: 2013-08-17
PAPER ACCEPTED: 2013-10-23
PUBLISHED ONLINE: 2014-07-06
DOI REFERENCE: https://doi.org/10.2298/TSCI130512171V
CITATION EXPORT: view in browser or download as text file
THERMAL SCIENCE YEAR 2014, VOLUME 18, ISSUE Supplement 1, PAGES [S29 - S38]
REFERENCES
  1. Reynolds, A., Friction Stir Welding of Aluminium Alloys, in: Handbook of Aluminium, Volume 2 (Eds. G. E. Totten, D. S. MacKenzie), Marcel Dekker; New York, 2003. pp. 579-700
  2. ***,"Friction-Stir-Welding-Of-Combat-Vehicles",
  3. www.twi.co.uk/news-events/case-studies/-257/
  4. Johnsen, M. R., Friction Stir Welding takes off at Boeing, The Welding Journal, 78 (1999), 2, pp. 35-39
  5. ***, SAPA group, www.sapagroup.com/upload/fsw%20eng.pdf
  6. Veljić, D. et al., Heat Generation During Plunge Stage in Friction Stir Welding, Thermal Science (2013) doi:10.2298/TSCI120301205V
  7. Veljić, D., Technology of Friction Stir Welding of Aluminium Alloys (in Serbian), M.Sc. thesis, University of Belgrade, Belgrade, Serbia, 2006
  8. Veljić, D. et al., Numerical Simulation of the Plunge Stage in Friction Stir Welding, Structural Integrity and Life, 11 (2011), 2, pp. 131-134
  9. Veljić, D. et al., A Coupled Thermo-Mechanical Model of Friction Stir Welding, Thermal Science, 16 (2012), 2, pp. 527-534
  10. Ivanović, I. et al., Numerical Study of Transient Three-dimensional Heat Conduction Problem with a Moving Heat Source, Thermal Science, 15 (2011), 1, pp. 257-266
  11. Perović, M. et al., Friction-stir Welding of High-Strength Aluminium Alloys and a Numerical Simulation of the Plunge Stage, Materials and Technologies, 46 (2012), 3, pp. 105-111
  12. Berković, M. et al., Analysis of Welded Joints by Applying the Finite Element Method, Structural Integrity and Life, 4 (2004), 2, pp. 75-83
  13. Song, M., Kovaèević, R., Numerical and Experimental Study of the Heat Transfer Process in Friction Stir Welding, Journal of Engineering Manufacture, 217 (2003), 1, pp. 73-85
  14. Chen, C. M., Kovaèević, R., Finite Element Modeling of Friction Stir Welding - Thermal and Thermomechanical Analysis, International Journal of Machine Tools & Manufacture, 43 (2003), 13, pp. 1319-1326
  15. ***, Certificate conformity, ALCOA International, Inc, Approved Certificate No. 47831, 1990
  16. Johnson, G. R., Cook, W. H., A Constitutive Model and Data for Metals Subjected to Large Strains, High Strain Rates and High Temperatures, Proceedings, 7th International Symposium on Ballistics, The Hague, The Netherlands, 1983, pp. 541-547
  17. ***, ASM International Aluminum 2024-T3 Data Sheet, asm.matweb.com/search/SpecificMaterial.asp?bassnum=MA2024T3
  18. ***, Dassault Systemes, Abaqus Analysis Manual, 2011
  19. Lesuer, D.R., Experimental Investigations of Material Models for Ti-6Al-4V Titanium and 2024-T3 Aluminum, Final Report, Department of Transportation, Washington DC, USA, 2000
  20. Veljić, D. et al., Thermo-mechanical Modeling of Friction Stir Welding, Proceedings, 4th International Conference on Innovative Technologies for Joining Advanced Materials, 2010, pp. 171-176
  21. Schmidt, H., Hattel, J., A Local Model for the Thermomechanical Conditions in Friction Stir Welding, Modelling & Simulation in Materials Science and Engineering, 13 (2005), 1, pp. 77-93
  22. Park, K., Development and Analysis of Ultrasonic Assisted Friction Stir Welding Process, Ph.D. thesis, University of Michigan, Ann Arbor, USA, 2009
  23. Arbegast, W., Application of Friction Stir Welding and Related Technologies, in: Friction Stir Welding and Processing (Eds. M. Mahoney, R. Mishra), ASM International, Materials Park, OH, 2007, pp. 273-308
PDF VERSION [DOWNLOAD]
Experimental and numerical thermo-mechanical analysis of friction stir welding of high-strength alluminium alloy

© 2024 Society of Thermal Engineers of Serbia. Published by the Vinča Institute of Nuclear Sciences, National Institute of the Republic of Serbia, Belgrade, Serbia. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution-NonCommercial-NoDerivs 4.0 International licence