Skip to main content
SpringerLink
Log in

Modeling the Material Flow and Heat Transfer in Reverse Dual-Rotation Friction Stir Welding

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

Reverse dual-rotation friction stir welding (RDR-FSW) is a novel modification of conventional friction stir welding (FSW) process. During the RDR-FSW process, the tool pin and the assisted shoulder are separated and rotate with opposite direction independently, so that there are two material flows with reverse direction. The material flow and heat transfer in RDR-FSW have significant effects on the microstructure and properties of the weld joint. A 3D model is developed to quantitatively analyze the effects of the separated tool pin and the assisted shoulder which rotate in reverse direction on the material flow and heat transfer during RDR-FSW process. Numerical simulation is conducted to predict the temperature profile, material flow field, streamlines, strain rate, and viscosity distributions near the tool. The calculated results show that as the rotation speed of the tool pin increases, the temperature near the tool gets higher, the zone with higher temperature expands, and approximately symmetric temperature distribution is obtained near the tool. Along the workpiece thickness direction, the calculated material flow velocity and its layer thickness near the tool get lowered because the effect of the shoulder is weakened as the distance away from the top surface increases. The model is validated by comparing the predicted values of peak temperature at some typical locations with the experimentally measured ones.

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

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

References

  1. R.S. Mishra and Z.Y. Ma, Friction Stir Welding and Processing, Mater. Sci. Eng. R., 2005, 50(1), p 1–78

    Article  Google Scholar 

  2. L.E. Murr, A Review of FSW Research on Dissimilar Metal and Alloy Systems, J. Mater. Eng. Perform., 2010, 19(8), p 1071–1089

    Article  Google Scholar 

  3. Z. Kiss and T. Czigány, Applicability of Friction Stir Welding in Polymeric Materials, Period. Polytech. Mech. Eng., 2007, 51, p 15–18

    Article  Google Scholar 

  4. N. Mendes, A. Loureiro, C. Martins, P. Neto, and J.N. Pires, Effect of Friction Stir Welding Parameters on Morphology and Strength of Acrylonitrile Butadiene Styrene Plate Welds, Mater. Des., 2014, 58, p 457–464

    Article  Google Scholar 

  5. R. Nandan, T. DebRoy, and H.K.D.H. Bhadeshia, Recent Advances in Friction Stir Welding—Process, Weldment Structure and Properties, Prog. Mater. Sci., 2008, 53(6), p 980–1023

    Article  Google Scholar 

  6. G.Q. Chen, Q.Y. Shi, Y. Fujiya, and T. Horie, Simulation of Metal Flow During Friction Stir Welding Based on the Model of Interactive Force Between Tool And Material, J. Mater. Eng. Perform., 2014, doi:10.1007/s11665-014-0886-y

    Google Scholar 

  7. P.A. Colegrove and H.R. Shercliff, CFD Modelling of Friction Stir Welding of Thick Plate 7449 Aluminium Alloy, Sci. Technol. Weld. Join., 2006, 11(4), p 429–441

    Article  Google Scholar 

  8. M. Grujicic, G. Arakere, B. Pandurangan, J.M. Ochterbeck, C.-F. Yen, B.A. Cheeseman, A.P. Reynolds, and M.A. Sutton, Computational Analysis of Material Flow During Friction Stir Welding of AA5059 Aluminum Alloys, J. Mater. Eng. Perform., 2012, 21(9), p 1824–1840

  9. C.S. Wu, T. Zhang, and Y.H. Feng, Numerical Analysis of the Heat and Fluid Flow in a Weld Pool with a Dynamic Keyhole, Int. J. Heat Fluid Flow, 2013, 40, p 186–197

    Article  Google Scholar 

  10. P. Vilaça and W. Thomas, Friction Stir Welding Technology, Struct. Connect. Lightweight Met. Struct., 2012, 8, p 85–124

    Article  Google Scholar 

  11. S. Zimmer, L. Langlois, J. Laye, and B. Régis, Experimental Investigation of the Influence of the FSW Plunge Processing Parameters on the Maximum Generated Force and Torque, Int. J. Adv. Manuf. Technol., 2010, 47(1–4), p 201–215

    Article  Google Scholar 

  12. C. Chen and R. Kovacevic, Thermomechanical Modelling and Force Analysis of Friction Stir Welding by the Finite Element Method, Proc. IME C J. Mech. Eng. Sci., 2004, 218(5), p 509–519

    Article  Google Scholar 

  13. R. Rai, A. De, H.K.D.H. Bhadeshia, and T. DebRoy, Review: Friction Stir Welding Tools, Sci. Technol. Weld. Join., 2011, 16(4), p 325–342

    Article  Google Scholar 

  14. J.Q. Li and H.J. Liu, Effects of Welding Speed on Microstructures and Mechanical Properties of AA2219-T6 Welded by the Reverse Dual-Rotation Friction Stir Welding, Int. J. Adv. Manuf. Technol., 2013, 68, p 2071–2083

    Article  Google Scholar 

  15. W.M. Thomas, I.M. Norris, D.G. Staines, and E.R. Watts, Friction Stir Welding—Process Developments and Variant Techniques, The SME Summit, Oconomowoc, Milwaukee, USA, August 3-4, 2005.

  16. J.Q. Li and H.J. Liu, Characteristics of the Reverse Dual-Rotation Friction Stir Welding Conducted on 2219-T6 Aluminum Alloy, Mater. Des., 2013, 45, p 148–154

    Article  Google Scholar 

  17. R.K. Uyyuru and S.V. Kailas, Numerical Analysis of Friction Stir Welding Process, J. Mater. Eng. Perform., 2006, 15(5), p 505–518

    Article  Google Scholar 

  18. W. Li, Z. Zhang, J. Li, and Y.J. Chao, Numerical Analysis of Joint Temperature Evolution During Friction Stir Welding Based on Sticking Contact, J. Mater. Eng. Perform., 2012, 21(9), p 1849–1856

    Article  Google Scholar 

  19. H.H. Cho, S.T. Hong, J.H. Roh, H.S. Choi, S.H. Kang, R.J. Steel, and H.N. Han, Three-Dimensional Numerical and Experimental Investigation on Friction Stir Welding Processes of Ferritic Stainless Steel, Acta Mater., 2013, 60, p 2649–2661

    Article  Google Scholar 

  20. C.S. Wu, W.B. Zhang, L. Shi, and M. Chen, Visualization and Simulation of Plastic Material Flow in Friction Stir Welding of 2024 Aluminium Alloy Plates, Trans. Nonferrous Met. Soc. China, 2012, 22(6), p 1445–1451

    Article  Google Scholar 

  21. D.M. Neto and P. Neto, Numerical Modeling of Friction Stir Welding Process: A Literature Review, Int. J. Adv. Manuf. Technol., 2013, 65, p 115–126

    Article  Google Scholar 

  22. R. Nandan, G.G. Roy, T.J. Liener, and T. DebRoy, Three-Dimensional Heat and Material Flow During Friction Stir Welding of Mild Steel, Acta Mater., 2007, 55(3), p 883–895

    Article  Google Scholar 

  23. S.D. Giudice, C. Nonino, and S. Savino, Effects of Viscous Dissipation and Temperature Dependent Viscosity in Thermally and Simultaneously Developing Laminar Flows in Microchannels, Int. J. Heat Fluid Flow, 2007, 28, p 15–27

    Article  Google Scholar 

  24. R. Nandan, G.G. Roy, and T. DebRoy, Numerical Simulation of Three-Dimensional Heat Transfer and Plastic Flow During Friction Stir Welding, Metall. Mater. Trans. A, 2006, 37(4), p 1247–1259

    Article  Google Scholar 

  25. T. Sheppard and A. Jackson, Constitutive Equations for Use in Prediction of Flow Stress During Extrusion of Aluminium Alloys, Mater. Sci. Technol., 1997, 13(3), p 203–209

    Article  Google Scholar 

  26. A. Arora, R. Nandan, A.P. Reynolds, and T. DebRoy, Torque, Power Requirement and Stir Zone Geometry in Friction Stir Welding Through Modeling and Experiments, Scr. Mater., 2009, 60(1), p 13–16

    Article  Google Scholar 

  27. H. Schmidt and J. Hattel, Modelling Heat Flow Around Tool Probe in Friction Stir Welding, Sci. Technol. Weld. Join., 2005, 10(2), p 176–186

    Article  Google Scholar 

  28. T.J. Lienert, W.L. Stellwag, Jr., B.B. Grimmett, and R.W. Warke, Friction Stir Welding Studies on Mild Steel, Weld. J., 2003, 82, p 1s–9s

    Article  Google Scholar 

  29. M. Mehta, K. Chatterjee, and A. De, Monitoring Torque and Traverse Force in Friction Stir Welding from Input Electrical Signatures of Driving Motors, Sci. Technol. Weld. Join., 2013, 18(3), p 191–197

    Article  Google Scholar 

  30. H. Atharifar, D. Lin, and R. Kovacevic, Numerical and Experimental Investigations on the Loads Carried by the Tool During Friction Stir Welding, J. Mater. Eng. Perform., 2009, 18(4), p 339–350

    Article  Google Scholar 

  31. S.V. Patankar and D.B. Spalding, A Calculation Procedure for Heat, Mass and Momentum Transfer in Three-Dimensional Parabolic Flows, Int. J. Heat. Mass. Transf., 1972, 15, p 1787–1806

    Article  Google Scholar 

  32. H. Schmidt, T.L. Dickerson, and J. Hattel, Material Flow in Butt Friction Stir Welds in AA2024-T3, Acta Mater., 2006, 54, p 1199–1209

    Article  Google Scholar 

Download references

Acknowledgment

The authors are grateful to the financial support for this research from the State Key Laboratory of Advanced Welding and Joining at Harbin Institute of Technology in China (Grant No. AWJ-Z13-02), and the Sino-German Center for the Promotion of Science (Grant No. GZ-739).

Author information

Authors and Affiliations

  1. MOE Key Lab for Liquid-Solid Structure Evolution and Materials Processing, Institute of Materials Joining, Shandong University, Jinan, 250061, China

    L. Shi & C. S. Wu

  2. State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, 150001, China

    H. J. Liu

Authors
  1. L. Shi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. C. S. Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. H. J. Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to C. S. Wu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Shi, L., Wu, C.S. & Liu, H.J. Modeling the Material Flow and Heat Transfer in Reverse Dual-Rotation Friction Stir Welding. J. of Materi Eng and Perform 23, 2918–2929 (2014). https://doi.org/10.1007/s11665-014-1042-4

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-014-1042-4

Keywords

Search

Navigation