Skip to main content
SpringerLink
Log in

Theoretical aspects and design of a numerical model for friction tapered hydro-pillar processing of AISI4140 steel

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper considers the theoretical aspects required for the development of a coupled two-dimensional axi-symmetrical computational fluid dynamics (CFD) and heat transfer model for the friction taper hydro-pillar process (FTHPP). The model applies the plasticised material movement during welding as the laminar, viscous flow of a non-Newtonian fluid, while making use of a dynamic mesh to simulate the continuous deformation of plasticised material at the friction interface. The plastic material flows through a stationary discretized flow domain not requiring a moving mesh, resulting in the Eulerian CFD approach being effective - this CFD material flow model thus avoids the requirement for re-meshing. The material properties are entered via a viscosity function used to describe the flow stress, locally dependent on material strain rate and temperature. A non-linear multiphysics problem exists as the frictional and viscous heating act as heat sources. The simulation model applies an iterative approach for coupling the plastic deformation flow analysis with the thermal analysis. Strain rate and temperature distribution of the welding material mutually affect each other, as the flow stress is temperature-dependent and the plastic work (adiabatic shear) performed during the process generates heat, in addition to heat added by friction. Isotropic temperature-dependent thermo-physical properties are required and thus incorporated into the model. A successfully coupled simulation is presented with the thermal response analysis delivering the temperature distribution through the weld for which process temperature and subsequent hardness plots are drafted. Measurements obtained from experimental welds show favourable comparison, validating computed values. The presented work attempt to show how comprehensive numerical modelling, carried out through computer simulation, can assist in the analysis of the identified process characteristics during FTHPP.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23

Similar content being viewed by others

References

  1. Thomas W, Nicholas D. Leading Edge: Friction Hydro Pillar Processing. TWI Connect

  2. Hattingh D, Wielligh L, Thomas W (2015) Friction processing as an alternative joining technology for th enuclear industry. J S Afr Inst Mint Metall 115. https://doi.org/10.17159/2411-9717

  3. Thomas W, Nicholas D. The need for gas shielding - positive advantages for two friction processes. TWI Bulletin

  4. Hattingh D, Steuwer A, James M, Wedderburn I (2010) Residual stresses in overlapping friction taper stud welds. In: Proceedings of MECA-SENS 5, 5th International Conference on Mechanical Stress Evaluation by Neutrons and Synchrotron Radiation, Material Science Forum. vol. 652. Mito, Japan

  5. Hattingh D, Bulbring D, Els-Botes A, James M (2011) Process parameters influence on performance of friction taper stud welds in AISI 4140. Mater Des. https://doi.org/10.1016/j.matdes.2011.02.001

    Article  Google Scholar 

  6. Pinheiro G. Friction Hydro Pillar Processing of lightweight alloys: Bonding mechanisms and Joint properties. Institute of Materials Research, GKSS-Forschungszentrum, Germany

  7. Welding Handbook (2015) vol. 3. 9th ed. American Welding Society

  8. van Zyl C, Hattingh D (2019) Statistical Analysis of effects on weld response variables during Friction Hydro-Pillar Processing. R &D Journal of the South African Institution of Mechanical Engineering. https://doi.org/10.17159/2309-8988/2019/v35a2

  9. Vicharapu B, Kanan L, Clarke T, De A (2017) An investigation on friction hydro-pillar processing. Sci Technol Weld Join 22(7). https://doi.org/10.1080/13621718.2016.1274849

  10. Li G, Kobayashi S (1982) Rigid-Plastic Finite-Element analysis of plane strain rolling. J Eng Ind 104(1)

  11. Lindgren LE (2006) Numerical modelling of Welding. Computer Methods in Applied Mechanics and Engineering p. 195. https://doi.org/10.1016/j.cma.2005.08.018

  12. Goldak J, Bibby M, Moore R, Patel B (1986) Computer modelling of heat flow in welds. Metall Trans B p. 17

  13. Sluzalec A (1990) Thermal effects of Friction Welding. Int J Mech Sci 32(6):467–478. https://doi.org/10.1016/0020-7403(90)90153-A

    Article  Google Scholar 

  14. Balasubramanian V, Li YST, Crompton J, Soboyejo A, Katsube N, Soboyejo W (1999) A new friction law for the modelling of continuous drive friction welding: Applications to 1045 steel welds. Mater Manuf Process 14(6). https://doi.org/10.1080/10426919908914877

  15. Bendszak GB, North TH (1997) Modelling of fluid dynamics and heat transfer in Friction Welding. Trans Japan Welding Research 25(2):171–184

    Google Scholar 

  16. Bendszak GB, North TH, Li Z (1997) Numerical model for steady flow in friction welding. Acta Metall Mater 45(4):1735–1745

    Article  Google Scholar 

  17. Bhattacharya S, Majumber A, Basu S (1982) Mathematical modeling of metal extrusion process. J Eng Ind 104(1)

  18. Zhang Z, Dai G, Wu S, Dong L, Liu L (2009) Simulation of 42CrMo steel billet upsetting and its defects during forming process based on the software DEFORM-3D. Mater Sci Eng A p. 499. https://doi.org/10.1016/j.msea.2007.11.135

  19. Lin Y, Chen XM (2010) A combined Johnson-Cook and Zerilli-Armstrong model for hot compresses typical high-strength alloy steel. Comput Mater Sci 49(3). https://doi.org/10.1016/j.commatsci.2010.09.001

  20. Kim S, Lee Y, Byon S (2003) Study on constitutive relation of AISI4140 steel subject to large strain at elevated temperatures. J Mater Process Technol p. 140. https://doi.org/10.1016/S0924-0136(03)00742-8

  21. Fu L (1998) Duan L. The coupled deformation and heat flow analysis by finite element method during friction welding. 77:202–207

    Google Scholar 

  22. Seidel T, Reynolds A (2003) Two-dimensional friction stir welding process model based on fluid mechanics. Sci Technol Weld Join 8(3). https://doi.org/10.1179/136217103225010952

  23. Yilmaz M, Col M, Acet M (2002) Interface properties of aluminum/steel friction welded components. Mater Charact 49(5). https://doi.org/10.1016/S1044-5803(03)00051-2

  24. Frigaard O, Grong O, Midling O (2006) A process model for the friction stir welding of age hardened Aluminium alloys. Metall Mater Trans A 32(5). https://doi.org/10.1007/s11661-001-0128-4

  25. Landell R, Kanan L, Buzzatti D, Vicharapu B (2020) Material flow during hydro-pillar processing. Sci Technol Weld Join 25(3). https://doi.org/10.1080/13621718.2019.1679963

  26. van Zyl C. Process heat flow model for temperature and hardness prediction during Friction Taper Stud Welding of AISI 4140 [PhD Thesis]. South Africa

  27. Mapelli C, Corna C, Magni F (2008) Simulation of plastic deformation processes through a navier-stokes approach. In: Cammarata G, Petrone G, editors. Modelling and Simulation. Milan p. 223–232

  28. Lin Y, Chen M, Zhong J (2008) Constitutive modeling for elevated temperature flow behavior of 42CrMo steel. Comput Mater Sci p. 42. https://doi.org/10.1016/j.commatsci.2007.08.011

  29. Schmidt H, Hattel J (2004) Heat source models in simulation of heat flow in Friction Stir Welding. Int J Offshore Polar Eng 14(4). 14th International Offshore and Polar Engineering Conference

  30. Berman A, Drummond C, Israelachvili J (2006) Amontons’ law at the molecular level. Tribol Lett 4(2). https://doi.org/10.1023/A:1019103205079

  31. Blau P (2001) The significance and use of the friction coefficient. Tribol Int 34(9):585–591. https://doi.org/10.1016/S0301-679X(01)00050-0

    Article  Google Scholar 

  32. Chin R, Steif P (1995) A computational study of strain inhomogeneity in wire drawing. Int J Mach Tools Manuf 35(8). https://doi.org/10.1016/0890-6955(95)90403-9

  33. Peterson M, Calabrese S, Lis S, Jiang X (1994) Friction of alloys at high temperatures. J Mater Sci Technol p. 10

  34. Yagi A, Hyde T, Becker A, Williams J, Sun W (2005) Residual stress simulation in welded sections of P91 pipes. J Mater Process Technol. https://doi.org/10.1016/j.jmatprotec.2005.05.036

    Article  Google Scholar 

  35. Yue P, Zhou C, Feng J, Oliver-Gooch C, Hu H (2006) Phase-Field simulations of interfacial dynamics in viscoelastic fluids using finite elements with adaptive meshing. J Comput Phys p. 219. https://doi.org/10.1016/j.jcp.2006.03.016

  36. Vermolen F, Gharasoo M, Zitha P, Bruining J (2009) Numerical solutions of some diffuse interface problems: the cahn-hilliard equation and the model of thomas and windle. Int J Multiscale Comput Eng 7(6). https://doi.org/10.1615/IntJMultCompEng.v7.i6.40

Download references

Funding

The authors declare that no external funds, grants, or other support was received during the preparation of this manuscript.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Walter Sisulu University, East London, South Africa

    Carlo van Zyl

  2. Department of Mechanical Engineering, Nelson Mandela University, Port Elizabeth, South Africa

    Hannalie Lombard & Danie Hattingh

Authors
  1. Carlo van Zyl
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hannalie Lombard
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Danie Hattingh
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All authors contributed to the study conception and design. Material preparation, data collection and analysis were performed by Carlo van Zyl. The first draft of the manuscript was written by Carlo van Zyl and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

Corresponding author

Correspondence to Carlo van Zyl.

Ethics declarations

Competing Interests

The authors have no relevant financial or non-financial interest to disclose.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

van Zyl, C., Lombard, H. & Hattingh, D. Theoretical aspects and design of a numerical model for friction tapered hydro-pillar processing of AISI4140 steel. Int J Adv Manuf Technol 127, 4291–4306 (2023). https://doi.org/10.1007/s00170-023-11476-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11476-0

Keywords

Search

Navigation