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Research Papers

Friction Stir Welding Heat Transfer: Quasisteady Modeling and Its Validation

[+] Author and Article Information
Satish Perivilli1

Department of Mechanical Engineering, Tennessee Technological University, Cookeville, TN 38505svperivill21@tntech.edu

John Peddieson, Jie Cui

Department of Mechanical Engineering, Tennessee Technological University, Cookeville, TN 38505

1

Corresponding author.

J. Manuf. Sci. Eng 131(1), 011007 (Dec 29, 2008) (8 pages) doi:10.1115/1.3046138 History: Received November 18, 2007; Revised November 10, 2008; Published December 29, 2008

A quasisteady approach to friction stir welding (FSW) heat transfer modeling is proposed and implemented using FLUENT . An idealized model of the mechanical dissipation heating in FSW is employed. Selected numerical predictions based on the model are shown to capture most of the features of corresponding experimental data available in literature. It is concluded that the quasisteady formulation (due to its simplicity and moderate usage of computational resources) is an attractive alternative to more computationally intensive unsteady approaches to FSW modeling under some circumstances.

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Copyright © 2009 by American Society of Mechanical Engineers
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Figures

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Figure 1

A schematic of friction stir welding

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Figure 2

Schematic of a partial penetration FSW configuration

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Figure 3

Variation of actual and idealized yield stresses with temperature for aluminum alloys

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Figure 4

(a) Schematic of a 3D computational domain employed (not to scale), (b) lines at various angles along which the temperature distributions were studied for quasisteady analysis, and (c) reduced temperature distributions corresponding to a domain representative of an infinite length workpiece (L1/R=94.5, L2/R=377.95)

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Figure 5

Temperature distribution at cross sections 4 mm from the center of the pin for (a) partial penetration and (b) full penetration quasisteady models

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Figure 6

Reduced temperature distributions along the lines on the top surface for (a) partial penetration ((—) τ0,0, (◼) 120% τ0,0, (▲) 80% τ0,0) and (b) full penetration quasisteady models

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Figure 7

Comparison of quasisteady formulation results with Chao and Qi (1) along (a) longitudinal lines at different transverse locations and (b) transverse lines at different axial locations

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Figure 8

Comparison of quasisteady formulation results with Song and Kovacevic (2) at different rotational speeds

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