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Research Papers: JOINING

Effects of Nonconventional Tools on the Thermo-Mechanical Response of Friction Stir Welded Materials

[+] Author and Article Information
George N. Lampeas

Laboratory of Technology
and Strength of Materials,
Department of Mechanical Engineering
and Aeronautics,
University of Patras,
Patras 26 500, Greece
e-mail: labeas@mech.upatras.gr

Ioannis D. Diamantakos

Laboratory of Technology
and Strength of Materials,
Department of Mechanical Engineering
and Aeronautics,
University of Patras,
Patras 26 500, Greece
e-mail: diamond@mech.upatras.gr

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received September 24, 2014; final manuscript received February 9, 2015; published online September 4, 2015. Assoc. Editor: Jingjing Li.

J. Manuf. Sci. Eng 137(5), 051020 (Sep 04, 2015) (9 pages) Paper No: MANU-14-1488; doi: 10.1115/1.4029857 History: Received September 24, 2014

An investigation on the effect of two alternative friction stir welding (FSW) tool designs, namely, Bobbin tool and DeltaN tool, on the temperature profile, residual stress (RS), and distortion fields developing during FSW process is presented. The study is based on the semi-analytical calculation of the total heat generated during FSW. Subsequently, the calculated heat energy is applied as thermal load in a three-dimensional finite element (FE) thermo-mechanical model for the calculation of temperature history, RSs, and distortions. The overall methodology is validated through the comparison of the numerical results to respective experimental temperature measurements and distortions observations.

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References

Figures

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Fig. 1

Contact interfaces between tool and material in the cases of standard tool (a), Bobbin tool (b), and DeltaN tool (c)

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Fig. 2

Global FE thermo-mechanical model: (a) for the case of Bobbin tool FSW and (b) for DeltaN tool FSW

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Fig. 3

Comparison between experimental temperature measurements (EADS-France) and numerically calculated results for the case of Bobbin tool

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Fig. 4

Comparison between experimental temperature measurements (EADS-Germany) and numerically calculated results for the case of DeltaN tool

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Fig. 5

Qualitative comparison of the though-the-thickness temperature distributions between standard, Bobbin and DeltaN tool designs

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Fig. 6

Temperature-depended material properties (a) AA7449 and (b) AA2050 [20]

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Fig. 7

Equivalent through-the-thickness RS contour plots (a) Bobbin tool and (b) Delta-N tool FSW (values in Pa)

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Fig. 8

Bobbin tool RS distributions for different through-the-thickness planes (a) longitudinal direction, (b) transversal direction, and (c) out-of-plane direction; the through-the-thickness planes are defined in (d)

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Fig. 9

DeltaN tool RS distributions for different through-the-thickness planes (a) longitudinal direction, (b) transversal direction, and (c) out-of-plane direction; the through-the-thickness planes are defined in (d)

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Fig. 10

Distortion plots of the welded plate after the end of Bobbin FSW (a) and DeltaN FSW (b) (units in m)

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