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Analysis of defect formation mechanisms and their effects on weld strength during friction stir welding of Al 6061-T6 via experiments and finite element modeling

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Abstract

The formation of tunnel defects and cavities during friction stir welding of Al 6061 T6 alloy is symbiotically studied experimentally and numerically. A coupled Eulerian-Lagrangian finite element model is established to analyze the process, where the workpiece is modeled as an Eulerian body, and the tool as Lagrangian. The model was first validated by conducting experiments and correlating the force measured by a three-axis dynamometer and the temperature measured by a pyrometer with those predicted by the simulation model. The experimentally validated simulation model was used to find an optimum parameter set for the sound weld case. The material flow and peak temperatures reached are shown to be different in the formation of various subsurface defects. It is also shown that the maximum temperature reached during the formation of tunnel defects is below that of the solidus melting point and is higher in the case of cavity defect formation. The pin drives the material to the advancing side of the weld during cavity defect formation while it fails to do so during the formation of tunnel defects. At lower rotational speeds, tunnel defects are observed and at higher welding speeds, cavity defects are observed. A featured tooltip is used in the simulation, which facilitates the stirring action and leads to the formation of a sound weld. The model is validated by conducting experiments at the same welding parameters.

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  1. School of Mechanical Engineering, Purdue University, West Lafayette, IN, 47907, USA

    Abhishek Ajri, Nitin Rohatgi & Yung C. Shin

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  1. Abhishek Ajri
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  2. Nitin Rohatgi
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  3. Yung C. Shin
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Ajri, A., Rohatgi, N. & Shin, Y.C. Analysis of defect formation mechanisms and their effects on weld strength during friction stir welding of Al 6061-T6 via experiments and finite element modeling. Int J Adv Manuf Technol 107, 4621–4635 (2020). https://doi.org/10.1007/s00170-020-05353-3

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