0
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.

FIGURES IN THIS ARTICLE
<>
Copyright © 2015 by ASME
Your Session has timed out. Please sign back in to continue.

References

Thomas, M. W. , Nicholas, E. D. , Needham, J. C. , Church, M. G. , Templesmith, P. , and Dawes, C. J. , 1991, International Patent PCT/GB92/02203 and GB Patent 9125978.9.
Rai, R. , De, A. , Bhadeshia, H. K. D. H. , and DebRoy, T. , 2011, “Review: Friction Stir Welding Tools,” Sci. Technol. Weld. Joining, 16(4), pp. 325–342. [CrossRef]
Zhang, Y. N. , Cao, X. , Larose, S. , and Wanjara, P. , 2012, “Review of Tools for Friction Stir Welding and Processing,” Can. Metall. Q., 51(3), pp. 250–261. [CrossRef]
Chao, Y. J. , Qi, X. , and Tang, W. , 2003, “Heat Transfer in Friction Stir Welding—Experimental and Numerical Studies,” ASME J. Manuf. Sci. Eng., 125(1), pp. 138–145. [CrossRef]
Lockwood, W. D. , and Reynolds, A. P. , 2003, “Simulation of the Global Response of a Friction Stir Weld Using Local Constitutive Behavior,” Mater. Sci. Eng. A, 339(1–2), pp. 35–42. [CrossRef]
Santos, T. F. A. , Idagawa, H. S. , and Ramirez, A. J. , 2014, “Thermal History in UNS S32205 Duplex Stainless Steel Friction Stir Welds,” Sci. Technol. Weld. Joining, 19(2), pp. 150–156. [CrossRef]
Perivilli, S. , Peddieson, J. , and Cui, J. , 2009, “Friction Stir Welding Heat Transfer: Quasisteady Modeling and Its Validation,” ASME J. Manuf. Sci. Eng., 131(1), p. 011007. [CrossRef]
Chao, Y. J. , Qi, X. , and Tang, W. , 2003, “Heat Transfer in Friction Stir Welding—Experimental and Numerical Studies,” ASME J. Manuf. Sci. Eng., 125(1), pp. 138–145. [CrossRef]
Mukherjee, S. , and Ghosh, A. K. , 2008, “Simulation of a New Solid State Joining Process Using Single-Shoulder Two-Pin Tool,” ASME J. Manuf. Sci. Eng. 130(4), p. 041015. [CrossRef]
McCune, R. W. , Murphy, A. , Price, M. , and Butterfield, J. , 2012, “The Influence of Friction Stir Welding Process Idealization on Residual Stress and Distortion Predictions for Future Airframe Assembly Simulations,” ASME J. Manuf. Sci. Eng., 134(3), p. 031011. [CrossRef]
Fehrenbacher, A. , Smith, C. B. , Duffie, N. A. , Ferrier, N. J. , Pfefferkorn, F. E. , and Zinn, M. R. , 2014, “Combined Temperature and Force Control for Robotic Friction Stir Welding,” ASME J. Manuf. Sci. Eng., 136(2), p. 021007. [CrossRef]
Fehrenbacher, A. , Schmale, J. R. , Zinn, M. R. , and Pfefferkorn, F. E. , 2014, “Measurement of Tool-Workpiece Interface Temperature Distribution in Friction Stir Welding,” ASME J. Manuf. Sci. Eng., 136(2), p. 021009. [CrossRef]
Moraitis, G. A. , and Labeas, G. N. , 2010, “Investigation of Friction Stir Welding Process With Emphasis on Calculation of Heat Generated Due to Material Stirring,” Sci. Technol. Weld. Joining, 15(2), pp. 177–184. [CrossRef]
Nandan, R. , Debroy, T. , and Bhadeshia, H. , 2008, “Recent Advances in Friction-Stir Welding–Process, Weldment Structure and Properties,” Prog. Mater. Sci., 53(6), pp. 980–1023. [CrossRef]
Nandan, R. , Roy, G. G. , Lienert, T. J. , and Debroy, T. , 2007, “Three-Dimensional Heat and Material Flow During Friction Stir Welding of Mild Steel,” Acta Mater., 55(3), pp. 883–895. [CrossRef]
Schmidt, H. , Hattel, J. , and Wert, J. , 2004, “An Analytical Model for the Heat Generation in Friction Stir Welding,” Modell. Simul. Mater. Sci. Eng., 12(1), pp. 143–157. [CrossRef]
Ravichandran, G. , Rosakis, A. J. , Hodowany, J. , and Rosakis, P. , 2002, “On the Conversion of Plastic Work Into Heat During High-Strain-Rate Deformation,” AIP Conf. Proc., 620(1), pp. 557–562. [CrossRef]
European Research Project 'COst Effective INtegral Metallic Structures', Contract No. AST5-CT-030825, 2006.
Moraitis, G. , 2009, “Thermomechanical Simulation of Friction Stir and Laser Beam Innovative Welding Processes,” Ph.D. thesis, University of Patras, Greece.
Khandkar, M. Z. H. , Khan, J. A. , Reynolds, A. P. , and Sutton, M. A. , 2006, “Predicting Residual Thermal Stresses in Friction Stir Welded Metals,” J. Mater. Process. Technol., 174(1–3), pp. 195–203. [CrossRef]
Yan, D.-Y. , Wu, A.-P. , Silvanus, J. , and Shi, Q.-Y. , 2011, “Predicting Residual Distortion of Aluminum Alloy Stiffened Sheet After Friction Stir Welding by Numerical Simulation,” Mater. Des., 32(4), pp. 2284–2291. [CrossRef]

Figures

Grahic Jump Location
Fig. 1

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

Grahic Jump Location
Fig. 2

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

Grahic Jump Location
Fig. 3

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

Grahic Jump Location
Fig. 4

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

Grahic Jump Location
Fig. 5

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

Grahic Jump Location
Fig. 6

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

Grahic Jump Location
Fig. 7

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

Grahic Jump Location
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)

Grahic Jump Location
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)

Grahic Jump Location
Fig. 10

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

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In