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Generated forces and heat during the critical stages of friction stir welding and processing

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Abstract

The solid-state behavior of friction stir welding process results in violent mechanical forces that should be mitigated, if not eliminated. Plunging and dwell time are the two critical stages of this welding process in terms of the generated forces and the related heat. In this study, several combinations of pre-decided penetration speeds, rotational speeds, tool designs, and dwell time periods were used to investigate these two critical stages. Moreover, a coupled-field thermal-structural finite element model was developed to validate the experimental results and the induced stresses. The experimental results revealed the relatively large changes in force and temperature during the first two stages compared with those during the translational tool movement stage. An important procedure to mitigate the undesired forces was then suggested. The model prediction of temperature values and their distribution were in good agreement with the experimental prediction. Therefore, the thermal history of this non-uniform heat distribution was used to estimate the induced thermal stresses. Despite the 37% increase in these stresses when 40 s dwell time was used instead of 5 s, these stresses showed no effect on the axial force values because of the soft material incidence and stir effects.

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Authors and Affiliations

  1. Faculty of Mechanical Engineering, University Teknikal Malaysia Melaka (UTeM), Malacca, Malaysia

    Sadiq Aziz Hussein, Abd Salam Md Tahir & R. Izamshah

  2. Foundation of Technical Education, Baghdad, Iraq

    Sadiq Aziz Hussein

Authors
  1. Sadiq Aziz Hussein
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  2. Abd Salam Md Tahir
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  3. R. Izamshah
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Corresponding author

Correspondence to Abd Salam Md Tahir.

Additional information

Recommended by Associate Editor Young Whan Park

Sadiq Aziz Hussein was born in Iraq on Aug 16, 1976. He received the B.C. and M.S degrees in Department of Mechanical Engineering, Baghdad University. Currently, he is a Senior Lecturer in the Foundation of Technical Education, Baghdad, Iraq and a Ph.D. student at the Faculty of Mechanical Engineering, University Teknikal Malaysia Melaka (UTeM), Malacca, Malaysia. His research interests are in the area of simulation, friction stir welding, and hybrid structures.

Abd Salam Md Tahir works as an Associate Professor in the Faculty of Mechanical Engineering, Universiti Teknikal Malaysia Melaka (UTeM), Malacca, Malaysia. He received his B.Sc (Mech Eng) from Glasgow University, Scotland, UK, MSc (Applied Mechanics) from UMIST, UK and formerly Ph.D. student in Fatigue and Fracture at The University of Sheffield, UK. His current research interest includes plasticity and metal forming, fatigue and fracture under mixed-mode loadings and friction stir welding.

R. Izamshah works as a Senior Lecturer in the Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka. He received his B.E. degree from Universiti Teknologi MARA, Malaysia, MSc. degree from University of Birmingham, UK and Ph.D. in Manufacturing Engineering from RMIT University, Australia. Currently, he is a visiting professor at Tokushima University, Japan. He has published many research papers and has been awarded Thatcher Bros Prize from Institute of Mechanical Engineering, UK for the best paper on manufacturing industries and mechanical engineering in 2012. His current research interest includes precision machining, numerical simulation and optimization.

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Hussein, S.A., Tahir, A.S.M. & Izamshah, R. Generated forces and heat during the critical stages of friction stir welding and processing. J Mech Sci Technol 29, 4319–4328 (2015). https://doi.org/10.1007/s12206-015-0930-3

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  • DOI: https://doi.org/10.1007/s12206-015-0930-3

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