Advertisement

Numerical simulation and experimental investigation of band patterns in bobbin tool friction stir welding of aluminum alloy

  • Q. Wen
  • W. Y. LiEmail author
  • Y. J. Gao
  • J. Yang
  • F. F. Wang
ORIGINAL ARTICLE
  • 44 Downloads

Abstract

A coupled Eulerian-Lagrangian (CEL) model was developed to investigate the formation mechanism of band pattern (BP) during bobbin tool friction stir welding (BTFSW) process. The Johnson-Cook constitutive model which combines the strain rate and temperature effects in the material flow stress was used. The workpiece was modeled by the Eulerian formulation, while the tool was characterized by the Lagrangian formulation. The numerical analysis results agree well with experimental observations. The band structures with various sizes were discovered in the BP zone. Both the experimental and numerical analysis results indicate the BP zone forms on the advancing side of the joint. This is because the converged material flow is produced by both shoulders while being driven by the probe. The peak temperature, along the thickness of the BP zone, increased at the beginning followed by a decrease further away from the upper surface. The peak temperature obtained near the lower surface is slightly higher than that near the upper surface.

Keywords

Bobbin tool friction stir welding Band pattern Coupled Eulerian-Lagrangian Material flow 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Funding information

This study received financial support of the National Natural Science Foundation of China (No. 51705027), and the fund of the State Key Laboratory of Solidification Processing in NWPU (No. SKLSP201722).

References

  1. 1.
    Tier M, Rosendo T, Mazzaferro J, Mazzaferro C, dos Santos J, Strohaecker T (2017) The weld interface for friction spot welded 5052 aluminium alloy. Int J Adv Manuf Technol 90:267–276CrossRefGoogle Scholar
  2. 2.
    Habibnia M, Shakeri M, Nourouzi S, Givi MKB (2015) Microstructural and mechanical properties of friction stir welded 5050 Al alloy and 304 stainless steel plates. Int J Adv Manuf Technol 76:819–829CrossRefGoogle Scholar
  3. 3.
    Zou LS, Zou DW, Zhu YC, Wang HF (2018) Effect of process parameters on surface topography of friction stir welding. Int J Adv Manuf Technol 98:1807–1816CrossRefGoogle Scholar
  4. 4.
    Zhou L, Li GH, Liu CL, Wang J, Huang YX, Feng JC, Meng FX (2017) Effect of rotation speed on microstructure and mechanical properties of self-reacting friction stir welded Al-Mg-Si alloy. Int J Adv Manuf Technol 89:3509–3516CrossRefGoogle Scholar
  5. 5.
    Zhao S, Bi QZ, Wang YH, Shi J (2017) Empirical modeling for the effects of welding factors on tensile properties of bobbin tool friction stir-welded2219-T87 aluminum alloy. Int J Adv Manuf Technol 90:1105–1118CrossRefGoogle Scholar
  6. 6.
    Huang YX, Wan L, Lv SX, Feng JC (2013) Novel design of tool for joining hollow extrusion by friction stir welding. Sci Technol Weld Join 18:239–246CrossRefGoogle Scholar
  7. 7.
    Huang YX, Wan L, Huang TF, Lv Z, Zhou L (2016) The weld formation of self-support friction stir welds for aluminum hollow extrusion. Int J Adv Manuf Technol 87:1067–1075CrossRefGoogle Scholar
  8. 8.
    Wang FF, Li WY, Shen J, Hu SY, dos Santos JF (2015) Effect of tool rotational speed on the microstructure and mechanical properties of bobbin tool friction stir welding of Al-Li alloy. Mater Des 86:933–940CrossRefGoogle Scholar
  9. 9.
    Schneider JA, Nunes AC, Brendel MS (2010) The influence of friction stir weld tool form and welding parameters on weld structure and properties: nugget bulge in self-reacting friction stir welds. 8th International Symposium on Friction Stir Welding. Germany: Timmendorfer StrandGoogle Scholar
  10. 10.
    Liu HJ, Hou JC, Guo H (2013) Effect of welding speed on microstructure and mechanical properties of self-reacting friction stir welded 6061-T6 aluminum alloy. Mater Des 50:872–878CrossRefGoogle Scholar
  11. 11.
    Zhang HJ, Wang M, Zhang X, Yang GX (2015) Microstructural characteristics and mechanical properties of bobbin tool friction stir welded 2A14-T6 aluminum alloy. Mater Des 65:559–566CrossRefGoogle Scholar
  12. 12.
    Hou JC, Liu HJ, Zhao YQ (2014) Influences of rotation speed on microstructures and mechanical properties of 6061-T6 aluminum alloy joints fabricated by self-reacting friction stir welding tool. Int J Adv Manuf Technol 73:1073–1079CrossRefGoogle Scholar
  13. 13.
    Zhou L, Li GH, Liu CL, Wang J, Huang YX, Feng JC (2017) Microstructural characteristics and mechanical properties of Al-Mg-Si alloy self-reacting friction stir welded joints. Sci Technol Weld Join 22:438–445CrossRefGoogle Scholar
  14. 14.
    Shi L, Wu CS, Sun Z (2017) An integrated model for analysing the effects of ultrasonic vibration on tool torque and thermal processes in friction stir welding. Sci Technol Weld Join 23:1–15Google Scholar
  15. 15.
    Sun TZ, Roy MJ, Strong D, Withers PJ, Prangnell PB (2017) Comparison of residual stress distributions in conventional and stationary shoulder high-strength aluminum alloy friction stir welds. J Mater Process Technol 242:92–100CrossRefGoogle Scholar
  16. 16.
    Dialami N, Cervera M, Chiumenti M, Saracibar CA (2017) A fast and accurate two-stage strategy to evaluate the effect of the probe tool profile on metal flow, torque and forces in friction stir welding. Int J Mech Sci 122:215–227CrossRefGoogle Scholar
  17. 17.
    Shokri V, Sadeghi A, Sadeghi MH (2018) Thermomechanical modeling of friction stir welding in a Cu-DSS dissimilar joint. J Manuf Process 31:46–55CrossRefGoogle Scholar
  18. 18.
    Cao JY, Wang M, Kong L, Yin YH, Guo LJ (2017) Numerical modeling and experimental investigation of material flow in friction spot welding of Al 6061-T6. Int J Adv Manuf Technol 89:2129–2139CrossRefGoogle Scholar
  19. 19.
    Al-Badour F, Merah N, Shuaib A, Bazoune A (2013) Coupled Eulerian Lagrangian finite element modeling of friction stir welding processes. J Mater Process Technol 213:1433–1439CrossRefGoogle Scholar
  20. 20.
    Al-Badour F, Merah N, Shuaib A, Bazoune A (2014) Thermo-mechanical finite element model of friction stir welding of dissimilar alloys. Int J Adv Manuf Technol 72:607–617CrossRefGoogle Scholar
  21. 21.
    Kıral BG, Tabanoglu M, Serindag HT (2013) Finite element modeling of friction stir welding in aluminum alloys joint. Mathemat Computat Appl 18:122–131zbMATHGoogle Scholar
  22. 22.
    Li WY, Wang FF (2011) Modeling of continuous drive friction welding of mild steel. Mater Sci Eng A 528:5921–5926CrossRefGoogle Scholar
  23. 23.
    Huang YX, Xie YM, Meng XC, Lv ZL, Cao J (2018) Numerical design of high depth-to-width ratio friction stir welding. J Mater Process Technol 252:233–241CrossRefGoogle Scholar
  24. 24.
    Hossfeld M, Roos E (2013) A new approach to modelling friction stir welding using the CEL method. In: Int. Conf. Adv. Manuf. Eng. Technol. NEWTECH, pp 179–190Google Scholar
  25. 25.
    Schmidt H, Hattel J (2005) A local model for the thermomechanical conditions in friction stir welding. Model Simul Mater Sci Eng 13:77–93CrossRefGoogle Scholar
  26. 26.
    Bilici MK, Yukler AI (2012) Effects of welding parameters on friction stir spot welding of high density polyethylene sheets. Mater Des 33:545–550CrossRefGoogle Scholar
  27. 27.
    Esmaily M, Mortazavi N, Osikowicz W, Hindsefelt H, Svensson JE, Halvarsson M, Martin J, Johansson LG (2016) Bobbin and conventional friction stir welding of thick extruded AA6005-T6 profiles. Mater Des 108:114–125CrossRefGoogle Scholar
  28. 28.
    Tao Y, Zhang Z, Ni DR, Wang D, Xiao BL, Ma ZY (2016) Influence of welding parameter on mechanical properties and fracture behavior of friction stir welded Al-Mg-Sc joints. Mater Sci Eng A 612:236–245CrossRefGoogle Scholar
  29. 29.
    Yang Q, Mironov S, Sato YS, Okamoto K (2010) Material flow during friction stir spot welding. Mater Sci Eng A 527:4389–4398CrossRefGoogle Scholar
  30. 30.
    Singh P, Biswas P, Kore SD (2016) A three-dimensional fully coupled thermo-mechanical model for self-reacting friction stir welding of aluminium AA6061 sheets. J Phys Conf Ser 759:1–6Google Scholar
  31. 31.
    Commin L, Dumont M, Masse JE, Barrallier L (2009) Friction stir welding of AZ31 magnesium alloy rolled sheets: influence of processing parameters. Acta Mater 57:326–334CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Q. Wen
    • 1
  • W. Y. Li
    • 1
    Email author
  • Y. J. Gao
    • 2
  • J. Yang
    • 2
  • F. F. Wang
    • 3
  1. 1.State Key Laboratory of Solidification Processing, Shaanxi Key Laboratory of Friction Welding TechnologiesNorthwestern Polytechnical UniversityXi’anPeople’s Republic of China
  2. 2.Capital Aerospace Machinery CompanyBeijingPeople’s Republic of China
  3. 3.Beijing Institute of Astronautical Systems EngineeringChina Academy of Launch Vehicle TechnologyBeijingChina

Personalised recommendations