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Analysis of heat transfer and material flow in reverse dual-rotation friction stir welding

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Abstract

Reverse dual-rotation friction stir welding (RDR-FSW) is a novel variant of conventional FSW process. The key feature is that the tool pin and the assisted shoulder rotate reversely and independently during the process; thus, it has great potential to improve the weld quality and lower the welding loads through adjusting the rotating speeds of the tool pin and the assisted shoulder independently. In this study, a 3D model of RDR-FSW process is developed to conduct the numerical simulation of heat generation, material flow, and temperature profile during the process. Heat generated due to plastic deformation and friction at the tool-workpiece contact interfaces are both considered. Streamlines show that there are two material flows with reverse direction, which is beneficial to the uniformity of both the temperature and the microstructure at the advancing side and retreating side. The simulation results show that rotating speeds of the assisted shoulder and the tool pin have great effects on the shape and size of the thermo-mechanically affected zone (TMAZ). The calculated peak temperatures at typical locations match with the experimentally measured ones. It lays solid foundation to optimize the process parameters in RDR-FSW.

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Acknowledgments

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). The authors are grateful to the Editor, the Associate Editor, and anonymous reviewers for their insightful comments which have helped to improve the quality of the paper.

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Authors and Affiliations

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

    L. Shi & C. S. Wu

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

    C. S. Wu & H. J. Liu

Authors
  1. L. Shi
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  2. C. S. Wu
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  3. H. J. Liu
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Corresponding author

Correspondence to C. S. Wu.

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Doc. IIW-2550, recommended for publication by Study Group SG-212 “The Physics of Welding”

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Shi, L., Wu, C.S. & Liu, H.J. Analysis of heat transfer and material flow in reverse dual-rotation friction stir welding. Weld World 59, 629–638 (2015). https://doi.org/10.1007/s40194-015-0238-z

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  • DOI: https://doi.org/10.1007/s40194-015-0238-z

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