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Probing residual stresses in stationary shoulder friction stir welding process

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Abstract

Stationary shoulder friction stir welding (SSFSW) is a new variant of the conventional FSW with rotation of only the tool probe to reduce the rate of heat generation along the tool–workpiece interface and hence, weld joint residual stresses. Studies on the evolution of residual stresses in SSFSW are rare as the process is new. A detailed investigation on the evolution of welding-induced residual stress is reported here for SSFSW and the conventional FSW of four different aluminum alloys. A finite element method–based numerical model, JWRIAN-Hybrid, is used for the three-dimensional heat transfer and thermo-mechanical stress analyses. The computed results are validated extensively with the corresponding experimentally measured results. The results show approximately 10% to 20% reduction in the peak residual stresses in SSFSW under identical welding conditions.

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Acknowledgments

This article is based on the results obtained from a future pioneering project commissioned by the New Energy and Industrial Technology Development Organization (NEDO).

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Authors and Affiliations

  1. Joining and Welding Research Institute, Osaka University, Osaka, Japan

    B. Vicharapu, H. Liu, H. Fujii, K. Narasaki & N. Ma

  2. Indian Institute of Technology Bombay, Mumbai, India

    A. De

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  1. B. Vicharapu
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  2. H. Liu
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  3. H. Fujii
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Correspondence to B. Vicharapu.

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Appendices

Appendix 1

Table 4 The studies employed the JWRIAN for the residual stress analysis
Full size table

Appendix 2

The change of joint hardness in peak aged alloys is estimated following the Myhr and Grong model [38]. The dissolution of precipitates depends upon the isothermal holding time (t) and temperature (T). The model directly relates the fraction of remaining hardening precipitates available (f/fO) after the isothermal heat treatment with the resulting yield strength and hardness of the peak aged material (fO).

$$ \frac{f}{f_O}=1-{\left(\frac{t}{t^{\ast }}\right)}^n $$
(A1)

where α1 is the relative hardness and n (=0.5 by default) is a time exponent.

The analysis was simplified by scaling the dissolution time to a reference temperature TR at which the time for full dissolution is tR. Thus, the time (t) required for dissolution at any given temperature (T) is given as

$$ {t}^{\ast }={t}_R\times \exp \left(\frac{Q_E}{R}\right)\left(\frac{1}{T}-\frac{1}{T_R}\right) $$
(A2)

The relation between f/fO and t/t* is generally fitted into the master curve for most of the precipitation hardening aluminum alloys. The required data for master curve is generally obtained from a series of iso-thermal experiments [38]. The values of QE, tR, and TR for AA2219, AA6061, AA7010-T6, and AA7050-T6 are realized from the following references [15,16,17, 19]. The yield strength of the given alloy after the isothermal heat treatment is estimated by

$$ \frac{f}{f_O}=\frac{\sigma_Y-{\sigma}_{Y\_\mathit{\operatorname{MIN}}}}{\sigma_{Y\_\mathit{\operatorname{MAX}}}-{\sigma}_{Y\_\mathit{\operatorname{MIN}}}} $$
(A3)

Eq (A1) is integrated over the time for a series of small time increments (dt) and the resulting yield strength is estimated corresponding to the kinetic strength of the thermal cycle for the given alloy.

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Vicharapu, B., Liu, H., Fujii, H. et al. Probing residual stresses in stationary shoulder friction stir welding process. Int J Adv Manuf Technol 106, 1573–1586 (2020). https://doi.org/10.1007/s00170-019-04570-9

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