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Modeling of friction-stir butt-welds and its application in automotive bumper impact performance Part 1. Thermo-mechanical weld process modeling

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Abstract

The demand for better structural performance in joining of components for road vehicles prompts the implementation of aluminum alloy friction stir welding technology in the automotive industry. The aim of current study is the creation of a 3-D finite element (FE) friction thermal model and stir welding (FSW) process of dissimilar aluminum alloy and for the estimation of crash worthiness performance of FSW fabricated shock absorber assembly. Thermo mechanical simulations and analysis are performed to understand the thermal behavior in the FSW weld zones. The developed models are correlated against published experimental results in terms of temperature profile of the weld zone. The developed models are then implemented for fabricating vehicle bumper parts to illustrate the performance of FSW welded components during an impact. Customary sled testing for low-speed guard necessities is performed utilizing a grating blend welded test apparatus at Wichita State University (WSU) at the National Institute for Aviation Research (NIAR). A few guard congregations are then appended to the test installation utilizing FSW and conventional Gas bend GMAW welding strategies. Numerical models are likewise created where limited component investigation is utilized to contrast the anticipated harm and the real harm maintained by both of the FSW and GMAW manufactured guards. During the research, a new FSW weld mold is created that allows for a better representation of the desired progressive crack propagation. The FSW fabricated bumper based on the Johnson-Cook failure model yields better failure prediction and is in good agreement to the test. The results from this study provide a guideline for an accurate finite element modeling of a FSW fabricated components and their application in the crashworthiness of such structural components.

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Author information

Authors and Affiliations

  1. Wichita State University, Wichita, KS, USA

    Sachin Patil, Yi Yang Tay, Farzad Baratzadeh & Hamid Lankarani

  2. Advanced Joining and Processing Laboratory, National Institute for Aviation Research, Wichita, KS, USA

    Farzad Baratzadeh

Authors
  1. Sachin Patil
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  2. Yi Yang Tay
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  3. Farzad Baratzadeh
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  4. Hamid Lankarani
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Corresponding author

Correspondence to Sachin Patil.

Additional information

Sachin Patil is a doctoral student of Dr. Hamid Lankarani, Mechanical Engineering at Wichita State University. He has specialized in the application of explicit integration techniques for crashworthiness and impact weld failure problems. He has over 15 years of expertise in the field of Numerical Simulations, Sensitivity and Reliability Studies and have the distinction of being qualified as crash analyst with weld failure propagation. He has authored scholarly articles in the crashworthiness, optimization field, in professional as well as major trade publications and consult on the use of numerical simulations using LS-DYNA/ABAQUS.

Hamid Lankarani is a Professor of Mechanical Engineering and a Senior Fellow of the National Institute for Aviation Research at Wichita State University. He began his professional career in 1981. Dr. Lankarani is one of the world’s leading researchers and educators in the field of impact dynamics, automotive and aircraft crashworthiness, occupant protection, and injury biomechanics.

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Patil, S., Tay, Y.Y., Baratzadeh, F. et al. Modeling of friction-stir butt-welds and its application in automotive bumper impact performance Part 1. Thermo-mechanical weld process modeling. J Mech Sci Technol 32, 2569–2575 (2018). https://doi.org/10.1007/s12206-018-0514-0

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  • DOI: https://doi.org/10.1007/s12206-018-0514-0

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