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Using a Coupled Thermal/Material Flow Model to Predict Residual Stress in Friction Stir Processed AlMg9Si

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Abstract

A coupled thermal/material flow model of friction stir processing is developed for friction stir processing of an as-cast AlSi9Mg aluminum alloy. By capturing material flow during processing, an asymmetric temperature distribution is generated with higher processing temperatures on the advancing side than on the retreating side. The temperature distribution from the coupled model is then incorporated into a thermomechanical model to predict the residual stress state after processing. These numerical results are compared with the residual stresses experimentally measured by the trepanation method. Experimental results show that the tensile residual stresses are higher on the advancing side than on the retreating side. The simulation successfully captures the asymmetric behavior of the residual stress profile, and the predicted maximum residual stress values show relatively good agreement with the experimental values. The simulated profile, however, is narrower than the experimental profile, yielding a smaller region of tensile residual stresses around the process zone than experimentally observed.

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Acknowledgments

The authors would like to acknowledge the AGH University of Science and Technology (Grant No. 11.11.110.295) for their support of this work.

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Authors and Affiliations

  1. Department of Mechanical and Manufacturing Engineering, College of Engineering and Computing, Miami University, Oxford, OH, USA

    C. Hamilton

  2. Department of the Testing of Materials Weldability and Welded Construction, Institute of Welding, Gliwice, Poland

    M. St. Węglowski & P. Sedek

  3. Faculty of Metal Engineering and Industrial Computer Science, AGH University of Science and Technology, Krakow, Poland

    S. Dymek

Authors
  1. C. Hamilton
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  2. M. St. Węglowski
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  3. S. Dymek
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  4. P. Sedek
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Correspondence to C. Hamilton.

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Hamilton, C., Węglowski, M.S., Dymek, S. et al. Using a Coupled Thermal/Material Flow Model to Predict Residual Stress in Friction Stir Processed AlMg9Si. J. of Materi Eng and Perform 24, 1305–1312 (2015). https://doi.org/10.1007/s11665-015-1402-8

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  • DOI: https://doi.org/10.1007/s11665-015-1402-8

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