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A coupled computational fluid dynamics approach as a viable tool for thermal history assessment of UNS S32205 duplex stainless steels friction stir welded joints

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Abstract

Friction stir welding is a manufacturing process with several positive outputs for duplex stainless steel joints, such as improved mechanical resistance and the maintenance of optimal phase fraction. Duplex steels are vastly used in naval and petrochemical operations, being commonly manufactured and joined via welding processes. Thus, there is a high demand for straightforward methods of thermal evaluation of friction stir welded joints. In this sense, numerical models are a practical tool for assessing the joints’ welding condition. However, the vast majority of works concerning numerical modeling of FSW of duplex steels are limited, by some considerations regarding the heat source modeling, by neglecting the material’s flow convective influence, and by omitting the thermomechanical properties of individual phases. This work focused on the development and application of a more complete coupled numerical model for friction stir welding of UNS S32205 plates in order to correlate processing conditions with microstructure evolution. A peak temperature of 1213 °C at the joint’s central line was observed. Distributions of temperature and material flow through the joint cross-section indicate that a more intense material flow at the retreating side favors coarser grain size. Simulation results indicated that the strain rate plays a more intense effect in microstructure development compared to the welding peak temperatures. The coupled numerical model was additionally used to obtain the temperature profile of the tool, which was thermally stable even after standing temperature values greater than 1200 °C. Even after 18 cm of welding procedure, thermal damage of the tool was not observed, leading to sound welded joints.

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Acknowledgements

The authors thank Brazilian and Portuguese funding agencies—Fundação de Amparo à Ciência e Tecnologia do Estado de Pernambuco (FACEPE), Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES), Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq), Financiadora de Estudos e Projetos (FINEP), Agência Nacional do Petróleo, Gás Natural e Biocombustíveis (ANP/Petrobras). The authors also acknowledge the experimental infrastructure of Laboratório Nacional de Nanotecnologia (LNNano) in Centro Nacional de Pesquisa em Energia e Materiais (CNPEM). TFAS also acknowledges the technical support, collaboration, and mentorship of Prof. Antonio Ramirez (Ohio State University). JPO acknowledges funding by national funds from FCT - Fundação para a Ciência e a Tecnologia, I.P., in the scope of the projects LA/P/0037/2020, UIDP/50025/2020 and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication – i3N. JS acknowledges the China Scholarship Council for funding the Ph.D. grant (CSC NO. 201808320394).

Funding

This work was supported by multiuser funding of Fundação de Amparo à Ciência e Tecnologia do Estado de Pernambuco (FACEPE) under grant number APQ-0964–3.03/21. TFAS also thank Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq) for scientific productivity scholarship (grant number 304741/2020–5). JPO and JS acknowledge Fundação para a Ciência e a Tecnologia (FCT—MCTES) for a its financial support via the project UID/00667/2020 (UNIDEMI). JS acknowledges the China Scholarship Council for funding the Ph.D. grant (CSC NO. 201808320394). JPO acknowledges the funding of CENIMAT/i3N by national funds through the FCT-Fundação para a Ciência e a Tecnologia, I.P., within the scope of multiannual financing of R&D units, reference UIDB/50025/2020–2023.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Universidade Federal de Pernambuco, Recife, Brazil

    Guilherme Gadelha de Sousa Figueiredo & Tiago Felipe de Abreu Santos

  2. Brazilian Institute for Material Joining and Coating Tecnologies (INTM), Universidade Federal de Pernambuco, Recife, Brazil

    Guilherme Gadelha de Sousa Figueiredo, Igor Jordão Marques & Tiago Felipe de Abreu Santos

  3. Brazilian Northeast Aerospace Network, Universidade Federal de Pernambuco, Recife, Brazil

    Lucas Oliveira Siqueira & Tiago Felipe de Abreu Santos

  4. UNIDEMI, Department of Mechanical and Industrial Engineering, NOVA School of Science and Technology, Universidade NOVA de Lisboa, Lisbon, Portugal

    Jiajia Shen & Joao Pedro Oliveira

  5. CENIMAT|i3N, Department of Materials Science, School of Science and Technology, NOVA University Lisbon, Caparica, Portugal

    Joao Pedro Oliveira

  6. Rua da Inovação, S/N, Cidade Universitária, P.O. Box 50740-540, Recife, Pernambuco, Brazil

    Tiago Felipe de Abreu Santos

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Contributions

G. G. S. Figueiredo: contributed to the development of numerical simulation, interpretation of numerical data, graphical planning, and framework.

I. J. Marques: contributed to the development of numerical simulation and microstructure data processing and discussion, the interpretation of numerical data, graphical planning, and a framework.

L. O. Siqueira: contributed to the development of numerical simulation, interpretation of numerical data, graphical planning, and framework.

J. Shen: contributed to the development of numerical simulation, gathered thermomechanical and thermophysical data of UNS S32205, and numerical data interpretation.

J. P. Oliveira: contributed to the development of numerical simulation, gathered thermomechanical and thermophysical data of UNS S32205, and numerical data interpretation.

T.F.A. Santos: contributed to the delimitation of the research topic, conducted experimental procedures of friction stir welding, gathered experimental temperature acquisition, supervised the findings of this work, and contributed to the interpretation of the results.

All the authors contributed to manuscript writing and reviewing.

Corresponding author

Correspondence to Tiago Felipe de Abreu Santos.

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de Sousa Figueiredo, G.G., Marques, I.J., Siqueira, L.O. et al. A coupled computational fluid dynamics approach as a viable tool for thermal history assessment of UNS S32205 duplex stainless steels friction stir welded joints. Weld World 67, 353–372 (2023). https://doi.org/10.1007/s40194-022-01416-z

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