Prediction of Peak Temperatures in Straight and Tapered Cylindrical Tool Profiles in Friction Stir Welding Using Improved Heat generation Models

Lawrence Olumide Jayesimi

Abstract


In this work, new model for the prediction of the peak temperatures in straight and tapered/conical cylindrical profiles FSW tools is presented through an improved analytical heat generation models. The developed models take into considerations that the welding process is a combination or mixture of the pure sliding and the pure sticking. From the obtained results, it is observed that increasing the tool rotational speed at constant weld speed increases the heat input, whereas the heat input decreases with an increase in the weld speed at constant tool rotational speed. Also, it was observed that the rate of heat generation at the shoulder is more in flat shoulder that the conical shoulder. The results in this work agreed with the experimental results. Therefore, the improved models could be used to estimate the heat generation in FSW tool.


Full Text:

PDF

References


W. M. Thomas, E. D. Nicholas, J. C. Needham, M. G. Murch, P. Temple-Smith and C. J. Dawes, Friction-Stir ButtWelding, GB Patent No. 9125978.8, International Patent Application No. PCT/ GB92/02203, 1991.

J. A. Schneider. Temperature Distribution and Resulting Metal Flow. In: Mishra RS, Mahoney MW, editors. Friction Stir Welding and Processing. Materials Park, OH (USA): ASM International, 2007, 71-110.

Y.J. Chao, X. Qi, W. Tang, Heat transfer in friction stir welding: experimental and numerical studies, ASME J. Manuf. Sci. Eng. 125 (2003), 138–145.

O. Frigaard, O. Grong, and O. T. Midling. A process model for friction stir welding of age hardening aluminium alloys. Metall. Mater. Trans. A. 32(2001), 1189–1200.

M. J. Russell and H. R. Shercliff H R 1st Int. Symp. On Friction Stir Welding (Thousand Oaks, California, USA), 1999.

P. A. Colegrove, H. R. Shercliff, R. Zettler. A model for predicting the heat generation and temperature in friction stir welding from the material properties. Sci. Technol. Weld. Joining 12 (2007), 284–297.

V. S. Gadakh, and A. Kumar. Heat generation model for taper cylindrical pin profile in friction stir welding. J. Mater.Res. Technol. 2(4) (2013), 370–375.

P. Ulysse. “Three-dimensional modeling of the friction stir-welding process.” Int’l Journal of Machine Tools and Manufacture, 42 (2002), 1549-1557.

S. Pala, M.P. Phanirajb,∗ Determination of heat partition between tool and workpiece during FSW of SS304 using 3D CFD modeling Journal of Materials Processing Technology 222 (2015) 280–286

M. B. Đurdanovic, M. M. Mijajlovic, D. S. Milcic, D. S. Stamenkovic, Heat Generation During Friction Stir Welding Process, Tribology in Industry,31 (2009), 1-2, pp. 8-14.

M. Mijajlović, and D. Milčić Analytical model for estimating the amount of heat generated during friction stir welding: Application on plates made of aluminium alloy. INTECH, Open Science 2024-T351, Chapter 11 (2012) 247–274.

T. K. Jauhari. Development of Multi-Component Device for Load Measurement and Temperature Profile for Friction Stir Welding Process [M.Sc Thesis]. Penang: UniversitiSains Malaysia; Unpublished. 2012.

A. Arora, T. Debroy, H. K. D. H. Bhadeshia. Back-of-the-envelope calculations in friction stir welding – velocities, peak temperature, torque, and hardness. Acta Mater 2011;59:2020–8.

A. Arora, R. Nandan, A. P. Reynolds, T. DebRoy. Torque, power requirement and stir zone geometry in friction stir welding through modeling and experiments. Scr Mater 60 (2009), 13–16.

N. S. M. El-Tayeb, K. O. Low, P. V. Brevern. On the surface and tribological characteristics of burnished cylindrical Al-6061. Tribol. Int 42(2009), 320–326

A. Devaraju, A. Kumar, B. Kotiveerachari. Influence of addition of Grp/Al2O3p with SiCp on wear properties of aluminum alloy 6061-T6 hybrid composites via friction stir processing. Trans Nonferrous Met Soc China 23(2013), 1275–1280

T. Sheppard and D. Wright. Determination of flow stress. Part 1 constitutive equation for aluminum alloys at elevated temperatures, Met. Technol., 6 (1979), 215–223.

T. Sheppard and A. Jackson. “Constitutive equations for use in prediction of flow stress during extrusion of aluminium alloys”, Materials Science and Technology, 13(3) (1997), 203–209.

R. K. Uyyuru, S. V. Kallas. Numerical analysis of friction stir welding process. J Mater Eng Perform, 15(2006), 505–518.

P. A. Colegrove, H. R. Shercliff. CFD Modelling of the friction stir welding of thick Plate 7449 aluminium alloy. Sci. Technol. Weld. Joining 11 (4) (2006), 429–441.

H. Wang, P. A. Colegrove, J. F. Dos Santos. Numerical investigation of the tool contact condition during friction stir welding of aerospace aluminium alloy. Comput Mater Sci. 71(2013), 101–108.

H. Su., C. Wu., M. Chen. Analysis of material flow and heat transfer in friction stir welding of aluminium alloys. China Weld (Engl Ed). 22 (2013):6–10.

H. Schmidt, J. Hattel, and J. Wert. An analytical model for the heat generation in friction stir welding. Modelling Simul. Mater. Sci. Eng. 12(2004): 143–157.

M. Z. H., Khandkar, J. A. Khan and R. A. Reynolds., Prediction of Temperature Distribution and Thermal History during Friction Stir Welding: Input Torque Based Model, Science and Technology of Welding and Joining., 8(3) (2003), 165-174.

Hamilton, C., Dymek, S. and Sommer, E. (2008). A Thermal Model for Friction Stir Welding in Aluminum Alloys. Int J Mach Tool Manuf. 2811201130.

Roy, G. G., Nandan, R. and DebRoy, T (2006). Dimensionless correlation to estimate peak temperature during friction stir welding. SciTechnol Weld Join; 11:606–8.

R. Nandan, G. Roy, and T. Debroy, Numerical simulation of three-dimensional heat transfer and plastic flow during friction stir welding. Metallurgical and Materials Transactions A, 2006. 37(4) (2006), 1247-1259.




DOI: http://dx.doi.org/10.2022/jmet.v10i1.1973

PRINT ISSN No.: 2180-1053
E ISSN No.: 2289-8123