A Finite Element Model to Simulate Defect Formation during Friction Stir Welding
In this study, a 3D coupled thermo-mechanical finite element model is developed to predict and analyze the defect formation during friction stir welding based on coupled Eulerian Lagrangian method. The model is validated by comparing the estimated welding temperature, processed zone shape and void s...
| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2017-07-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/7/7/256 |
| _version_ | 1811281755201601536 |
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| author | Zhi Zhu Min Wang Huijie Zhang Xiao Zhang Tao Yu Zhenqiang Wu |
| author_facet | Zhi Zhu Min Wang Huijie Zhang Xiao Zhang Tao Yu Zhenqiang Wu |
| author_sort | Zhi Zhu |
| collection | DOAJ |
| description | In this study, a 3D coupled thermo-mechanical finite element model is developed to predict and analyze the defect formation during friction stir welding based on coupled Eulerian Lagrangian method. The model is validated by comparing the estimated welding temperature, processed zone shape and void size with those obtained experimentally. The results compared indicate that the simulated temperature and the data measured are in good agreement with each other. In addition, the model can predict the plasticized zone shape and the presence of a void in the weld quite accurately. However, the void size is overestimated. The effects of welding parameters and tool pin profile are also analyzed. The results reveal that welding at low welding speed or high tool rotational speed could produce a smaller void. Moreover, compared to a smooth tool pin, a featured tool pin can enhance plastic flow in the weld and achieve defect-free weldment. The results are helpful for the optimization of the welding process and the design of welding tools. |
| first_indexed | 2024-04-13T01:39:19Z |
| format | Article |
| id | doaj.art-005992c2a3f14852b7ddb7971c00d4d3 |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-04-13T01:39:19Z |
| publishDate | 2017-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-005992c2a3f14852b7ddb7971c00d4d32022-12-22T03:08:15ZengMDPI AGMetals2075-47012017-07-017725610.3390/met7070256met7070256A Finite Element Model to Simulate Defect Formation during Friction Stir WeldingZhi Zhu0Min Wang1Huijie Zhang2Xiao Zhang3Tao Yu4Zhenqiang Wu5State Key Laboratory of Robotics, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, ChinaState Key Laboratory of Robotics, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, ChinaState Key Laboratory of Robotics, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, ChinaState Key Laboratory of Robotics, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, ChinaState Key Laboratory of Robotics, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, ChinaState Key Laboratory of Robotics, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, ChinaIn this study, a 3D coupled thermo-mechanical finite element model is developed to predict and analyze the defect formation during friction stir welding based on coupled Eulerian Lagrangian method. The model is validated by comparing the estimated welding temperature, processed zone shape and void size with those obtained experimentally. The results compared indicate that the simulated temperature and the data measured are in good agreement with each other. In addition, the model can predict the plasticized zone shape and the presence of a void in the weld quite accurately. However, the void size is overestimated. The effects of welding parameters and tool pin profile are also analyzed. The results reveal that welding at low welding speed or high tool rotational speed could produce a smaller void. Moreover, compared to a smooth tool pin, a featured tool pin can enhance plastic flow in the weld and achieve defect-free weldment. The results are helpful for the optimization of the welding process and the design of welding tools.https://www.mdpi.com/2075-4701/7/7/256friction stir weldingAl6061-T6material flowwelding detectfinite element simulationcoupled Eulerian Lagrangian |
| spellingShingle | Zhi Zhu Min Wang Huijie Zhang Xiao Zhang Tao Yu Zhenqiang Wu A Finite Element Model to Simulate Defect Formation during Friction Stir Welding Metals friction stir welding Al6061-T6 material flow welding detect finite element simulation coupled Eulerian Lagrangian |
| title | A Finite Element Model to Simulate Defect Formation during Friction Stir Welding |
| title_full | A Finite Element Model to Simulate Defect Formation during Friction Stir Welding |
| title_fullStr | A Finite Element Model to Simulate Defect Formation during Friction Stir Welding |
| title_full_unstemmed | A Finite Element Model to Simulate Defect Formation during Friction Stir Welding |
| title_short | A Finite Element Model to Simulate Defect Formation during Friction Stir Welding |
| title_sort | finite element model to simulate defect formation during friction stir welding |
| topic | friction stir welding Al6061-T6 material flow welding detect finite element simulation coupled Eulerian Lagrangian |
| url | https://www.mdpi.com/2075-4701/7/7/256 |
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