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Heat Transfer and Materials Flow Modeling of FSW for CuCrZr Alloy Using Experimentally Determined Thermo-Physical Properties

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Abstract

A three-dimensional heat transfer and material flow-based model using experimentally measured thermo-physical properties has been developed for friction stir welding (FSW) of Cu-0.8Cr-0.1Zr alloy. CuCrZr alloy is a precipitation-hardened copper alloy with good electrical and thermal conductivity and moderate strength at elevated temperatures. The temperature-dependent specific heat, thermal conductivity, and yield strength of the alloy were determined experimentally to develop a reliable and accurate numerical model. The results from numerical model were validated by performing suitable experiments for numerous tool rotational speeds and welding speeds during joining of 3-mm-thick CuCrZr alloy on a dedicated FSW machine. The temperature evolution across the welds was measured using thermocouples. The results from the developed numerical model were validated by comparing it with the measured weld thermal cycles, peak temperatures, and thermo-mechanically-affected zone (TMAZ) for various welds. Validation was also supported with microstructural evidences from the weld nugget zone and TMAZ. The developed model showed the capability to simulate FSW of CuCrZr alloy and predict the important results with reasonably good accuracy

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Acknowledgments

The authors express their gratitude to Shri U D Malshe, Engineering Design & Development Division, for showing a keen interest in the work. The authors are also thankful to Dr. G K Mallik of Post Irradiation Examination Division, Dr. S. Bhattacharya of Technical Physics Division, and Shri R K Mittal of Engineering Design & Development Division for providing support during the work. The authors would like to acknowledge the financial support provided by the Department of Atomic Energy, India, for project sanction no. 57/14/05/2019-BRNS. This work would not be possible without this support.

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Authors and Affiliations

  1. Engineering Design & Development Division, Bhabha Atomic Research Centre, Mumbai, 400085, India

    Kaushal Jha

  2. Homi Bhabha National Institute, Mumbai, 400094, India

    Kaushal Jha, R. N. Singh & G. K. Dey

  3. Advanced Materials Processing Research Group, Materials Science and Engineering, Indian Institute of Technology Gandhinagar, Gandhinagar, 382355, India

    Pankaj Sahlot, Amit Kumar Singh & Amit Arora

  4. Department of Mechanical Engineering, School of Technology, Pandit Deendayal Petroleum University, Gandhinagar, 382007, India

    Pankaj Sahlot

  5. Materials Science Division, Bhabha Atomic Research Centre, Mumbai, 400085, India

    Santosh Kumar

  6. Mechanical Metallurgy Division, Bhabha Atomic Research Centre, Mumbai, 400085, India

    R. N. Singh

  7. Materials Group, Bhabha Atomic Research Centre, Mumbai, 400085, India

    G. K. Dey

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  1. Kaushal Jha
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  2. Pankaj Sahlot
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Correspondence to Kaushal Jha.

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Manuscript submitted June 23, 2020; accepted November 9, 2020.

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Jha, K., Sahlot, P., Singh, A.K. et al. Heat Transfer and Materials Flow Modeling of FSW for CuCrZr Alloy Using Experimentally Determined Thermo-Physical Properties. Metall Mater Trans A 52, 680–690 (2021). https://doi.org/10.1007/s11661-020-06107-2

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  • DOI: https://doi.org/10.1007/s11661-020-06107-2

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