Skip to main content
SpringerLink
Log in

Developing a Finite Element Model for Thermal Analysis of Friction Stir Welding (FSW) Using Hyperworks

  • Conference paper
  • First Online:
Advances in Material Sciences and Engineering

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

Abstract

The study undertakes a three-dimensional finite element analysis of the friction stir welding (FSW) process of 6061-T6 aluminium alloy. The analysis investigates the temperature distribution and the fundamental knowledge of the process with respect to temperature difference in the material to be welded. HyperMesh® and HyperView® solver have been used from Altair Hyperworks® to analyse the process. Different traverse and rotational speeds have been applied in the model. The results of the study create a better understanding for peak temperature distribution. In addition, the results illustrate that the peak temperature during welding increases as the rotational speeds rises and the effect of the transverse speed on the temperature is found to be insignificant. Finally, comparisons with some published papers has been done in order to compare the results of the different finite element packages and summarize the advantages and disadvantages of each software.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 84.99
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 109.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

References

  1. Su H, Wu CS, Bachmann M, Rethmeier M (2015) Numerical modeling for the effect of pin profiles on thermal and material flow characteristics in friction stir welding. Mater Des 77:114–125

    Article  Google Scholar 

  2. Meyghani B, Awang MB, Emamian SS, Mohd Nor MKB, Pedapati SR (2017) A comparison of different finite element methods in the thermal analysis of friction stir welding (FSW). Metals 7:450

    Article  Google Scholar 

  3. Meyghani B, Awang M, Emamian S, Khalid NM (2017) Developing a finite element model for thermal analysis of friction stir welding by calculating temperature dependent friction coefficient. In: 2nd international conference on mechanical, manufacturing and process plant engineering, pp 107–126

    Chapter  Google Scholar 

  4. Miles M, Nelson T, Gunter C, Liu F, Fourment L, Mathis T (2018) Predicting recrystallized grain size in friction stir processed 304L stainless steel. J Mater Sci Technol

    Google Scholar 

  5. Argesi FB, Shamsipur A, Mirsalehi SE (2018) Dissimilar joining of pure copper to aluminum alloy via friction stir welding. Acta Metall Sinica (English Letters) 31:1183–1196

    Article  Google Scholar 

  6. Khandkar M, Khan JA, Reynolds AP (2003) Prediction of temperature distribution and thermal history during friction stir welding: input torque based model. Sci Technol Weld Joining 8:165–174

    Article  Google Scholar 

  7. Fehrenbacher A, Duffie NA, Ferrier NJ, Pfefferkorn FE, Zinn MR (2014) Effects of tool–workpiece interface temperature on weld quality and quality improvements through temperature control in friction stir welding. Int J Adv Manuf Technol 71:165–179

    Article  Google Scholar 

  8. Dialami N, Chiumenti M, Cervera M, de Saracibar CA (2015) Challenges in thermo-mechanical analysis of friction stir welding processes. Arch Comput Method Eng 1–37

    Google Scholar 

  9. Dialami N, Chiumenti M, Cervera M, Segatori A, Osikowicz W (2017) Enhanced friction model for friction stir welding (FSW) analysis: simulation and experimental validation. Int J Mech Sci 133:555–567

    Article  Google Scholar 

  10. Su H, Wu C, Pittner A, Rethmeier M (2014) Thermal energy generation and distribution in friction stir welding of aluminum alloys. Energy 77:720–731

    Article  Google Scholar 

  11. Meyghani B, Awang M, Emamian S (2016) A comparative study of finite element analysis for friction stir welding application. ARPN J Eng Appl Sci 11:12984–12989

    Google Scholar 

  12. Ansari MA, Samanta A, Behnagh RA, Ding H (2018) An efficient coupled Eulerian-Lagrangian finite element model for friction stir processing. Int J Adv Manuf Technol 1–14

    Google Scholar 

  13. Meyghani B, Awang M, Emamian S, Nor MKBM (2018) Thermal modelling of friction stir welding (FSW) using calculated young’s modulus values. In: The advances in joining technology. Springer, pp 1–13

    Google Scholar 

  14. Sun Z, Wu C, Kumar S (2018) Determination of heat generation by correlating the interfacial friction stress with temperature in friction stir welding. J Manuf Process 31:801–811

    Article  Google Scholar 

  15. Jaffarullah MS, Nur’Amirah Busu CYL, Saedon J, Armansyah MSBS, Jaffar A (2015) Simulation analysis of peak temperature in weld zones during friction stir process. J Teknol 76:77–81

    Google Scholar 

  16. Meyghani B, Awang M, Emamian S, Akinlabi E (2018) A comparison between temperature dependent and constant Young’s modulus values in investigating the effect of the process parameters on thermal behaviour during friction stir welding: Vergleich zwischen den temperaturabhängigen und konstanten Elastizitätsmodulwerten in der Untersuchung der Prozessparameter auf die Wärmewirkung beim Rührreibschweißen. Materialwiss Werkstofftech 49:427–434

    Article  Google Scholar 

  17. Meyghani B, Awang M, Emamian S (2017) A mathematical formulation for calculating temperature dependent friction coefficient values: application in friction stir welding (FSW). Defect Diff Forum 379:73–82

    Article  Google Scholar 

  18. Su H, Wu C, Pittner A, Rethmeier M (2013) Simultaneous measurement of tool torque, traverse force and axial force in friction stir welding. J Manuf Process 15:495–500

    Article  Google Scholar 

  19. Mishra RS, De PS, Kumar N (2014) Fundamentals of the friction stir process. In:Friction stir welding and processing. Springer, pp 13–58

    Google Scholar 

  20. Abdul-Sattar M, Tolephih MH, Jweeg MJ (2012) Theoretical and experimental investigation of transient temperature distribution in friction stir welding of AA 7020-T53. J Eng 18:693–709

    Google Scholar 

  21. Emamian S, Awang M, Hussai P, Meyghani B, Zafar A (2016) Influences of tool pin profile on the friction stir welding of AA6061. ARPN J Eng Appl Sci 11:12258–12261

    Google Scholar 

  22. Emamian S, Awang M, Yusof F, Hussain P, Mehrpouya M, Kakooei S et al (2017) A review of friction stir welding pin profile. In: Awang M (ed) 2nd international conference on mechanical, manufacturing and process plant engineering. Springer, Singapore, pp 1–18

    Google Scholar 

  23. Emamian S, Awang M, Yusof F, Hussain P, Meyghani B, Zafar A (2018) The effect of pin profiles and process parameters on temperature and tensile strength in friction stir welding of AL6061 alloy. In: The advances in joining technology. Springer, pp 15–37

    Google Scholar 

  24. Meyghani B, Awang MB (2018) Prediction of the temperature distribution during friction stir welding (Fsw) with a complex curved welding seam: application in the automotive industry. MATEC Web Conference, vol 225, p 01001

    Article  Google Scholar 

Download references

Acknowledgements

The authors would like to acknowledge the financial support from Universiti Teknologi PETRONAS (UTP), Bandar Seri Iskandar, Perak Darul Ridzuan, Malaysia and the financial support from YUTP-FRG grant cost center 0153AA-H18. Moreover, the authors would like to thank Altair Engineering Sdn Bhd, Malaysia and professor Wallace Kaufman for their endless support and collaboration.

Author information

Authors and Affiliations

  1. Institute of Materials Joining, Shandong University, Jinan, 250061, People’s Republic of China

    Bahman Meyghani

  2. Department of Mechanical Engineering, Faculty of Engineering, Universiti Teknologi PETRONAS, 32610, Bandar Seri Iskandar, Perak Darul Ridzuan, Malaysia

    Mokhtar Awang

Authors
  1. Bahman Meyghani
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mokhtar Awang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mokhtar Awang .

Editor information

Editors and Affiliations

  1. Department of Mechanical Engineering, Universiti Teknologi PETRONAS, Seri Iskandar, Perak, Malaysia

    Mokhtar Awang

  2. Department of Mechanical Engineering, Universiti Teknologi PETRONAS, Seri Iskandar, Perak, Malaysia

    Seyed Sattar Emamian

  3. Department of Mechanical Engineering, University of Malaya, Kuala Lumpur, Malaysia

    Farazila Yusof

Rights and permissions

Reprints and permissions

Copyright information

© 2020 Springer Nature Singapore Pte Ltd.

About this paper

Check for updates. Verify currency and authenticity via CrossMark

Cite this paper

Meyghani, B., Awang, M. (2020). Developing a Finite Element Model for Thermal Analysis of Friction Stir Welding (FSW) Using Hyperworks. In: Awang, M., Emamian, S., Yusof, F. (eds) Advances in Material Sciences and Engineering. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-13-8297-0_64

Download citation

  • DOI: https://doi.org/10.1007/978-981-13-8297-0_64

  • Published:

  • Publisher Name: Springer, Singapore

  • Print ISBN: 978-981-13-8296-3

  • Online ISBN: 978-981-13-8297-0

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Search

Navigation