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Stress state analysis of friction stir welding

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Abstract

Friction stir welding (FSW) is a well-known joining process applied to materials with low weldability. The FSW process is subjected to an elevated stress state; however, there is no theoretical stresses analysis for the process. In this paper, a stress analysis for FSW process is developed using the slab method. The governing differential equations are obtained through the force equilibrium and the von Mises yield criterion and solved to determine the stress state and the maximum axial force. Several models are proposed for the normal stress components based on Coulomb and Siebel friction laws. Additionally, a division into three zones of plastic deformation is used: stick zone, drag zone, and slip zone. The effect of the temperature increase is considered and the yield stress is modeled as a function of the angular speed. Experimental axial forces are measured in order to estimate the coefficient of friction. To verify the validity of the models, a validation point and published experimental results from the literature are used. The analytical results show a good agreement with the experiments, with an average percent error of 10%. The presented models provided a useful and quick knowledge, which can be applied in the dimensioning of the FSW process.

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Funding

This study was supported by the Brazilian Federal Agency for Support and Evaluation of Graduate Education (CAPES) and the Brazilian National Council for Scientific and Technological Development (CNPq), Grant 315473/2020-7.

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Authors and Affiliations

  1. Mechanical Engineering Department, COPPE and Polytechnic School, Universidade Federal do Rio de Janeiro, Cidade Universitária, Ilha do Fundão, Centro de Tecnologia, Bloco G, Sala 204, P.O. Box 68503, Rio de Janeiro, CEP 21941-972, Brazil

    Caroline Terra & Jose Luis L. Silveira

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  1. Caroline Terra
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  2. Jose Luis L. Silveira
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Contributions

CT: Conceptualization, methodology, software, data curation, writing-original draft, formal analysis, investigation, and project administration. JLLS: Conceptualization, methodology, investigation, resources, writing-review and editing, supervision, project administration, and funding acquisition.

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Correspondence to Jose Luis L. Silveira.

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Terra, C., Silveira, J.L.L. Stress state analysis of friction stir welding. Int J Adv Manuf Technol 121, 1123–1134 (2022). https://doi.org/10.1007/s00170-022-09262-5

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