Ultrasonic line source and its coupling with the tool induced heat generation and material flow in friction stir welding

To understand the synchronous interaction mechanism between the ultrasonic vibration exerted on the tool and the tool induced thermo-mechanical behavior in ultrasonic vibration-assisted friction stir welding (UVaFSW) process, the geometric shape of the contact surface between the horn and the tool w...

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Main Authors: Guanlan Zhang, ChuanSong Wu, Jinqiang Gao
Format: Article
Language:English
Published: Elsevier 2022-11-01
Series:Journal of Materials Research and Technology
Subjects:
Online Access:http://www.sciencedirect.com/science/article/pii/S2238785422014594
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author Guanlan Zhang
ChuanSong Wu
Jinqiang Gao
author_facet Guanlan Zhang
ChuanSong Wu
Jinqiang Gao
author_sort Guanlan Zhang
collection DOAJ
description To understand the synchronous interaction mechanism between the ultrasonic vibration exerted on the tool and the tool induced thermo-mechanical behavior in ultrasonic vibration-assisted friction stir welding (UVaFSW) process, the geometric shape of the contact surface between the horn and the tool was considered, and a previous point source of ultrasound was replaced by a line source which is more in line with the actual situation. With the established ultrasonic field model based on a line source of sound, the friction coefficient on the tool/workpiece interface was modified by considering the ultrasonic action from different directions. Combined with the computational fluid dynamics model, the UVaFSW process was numerically simulated. It was found that the line source of ultrasonic energy improved the computation accuracy of ultrasound pressure distribution, and ultrasonic antifriction effect greatly reduced the interfacial friction coefficient near the pin. The exerted ultrasonic vibration led to a slight overall decrease in total amount of heat generation in UVaFSW due to the dual effects of acoustic softening and ultrasonic antifriction. The model was validated by comparing the calculated thermal cycles and the thermo-mechanically affected zone with the experimental measurements.
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spelling doaj.art-cce8e8576af44544b16bc296a63458612022-12-22T04:23:14ZengElsevierJournal of Materials Research and Technology2238-78542022-11-0121502518Ultrasonic line source and its coupling with the tool induced heat generation and material flow in friction stir weldingGuanlan Zhang0ChuanSong Wu1Jinqiang Gao2MOE Key Lab for Liquid-Solid Structure Evolution and Materials Processing, Institute of Materials Joining, Shandong University, Jinan 250061, ChinaCorresponding author.; MOE Key Lab for Liquid-Solid Structure Evolution and Materials Processing, Institute of Materials Joining, Shandong University, Jinan 250061, ChinaMOE Key Lab for Liquid-Solid Structure Evolution and Materials Processing, Institute of Materials Joining, Shandong University, Jinan 250061, ChinaTo understand the synchronous interaction mechanism between the ultrasonic vibration exerted on the tool and the tool induced thermo-mechanical behavior in ultrasonic vibration-assisted friction stir welding (UVaFSW) process, the geometric shape of the contact surface between the horn and the tool was considered, and a previous point source of ultrasound was replaced by a line source which is more in line with the actual situation. With the established ultrasonic field model based on a line source of sound, the friction coefficient on the tool/workpiece interface was modified by considering the ultrasonic action from different directions. Combined with the computational fluid dynamics model, the UVaFSW process was numerically simulated. It was found that the line source of ultrasonic energy improved the computation accuracy of ultrasound pressure distribution, and ultrasonic antifriction effect greatly reduced the interfacial friction coefficient near the pin. The exerted ultrasonic vibration led to a slight overall decrease in total amount of heat generation in UVaFSW due to the dual effects of acoustic softening and ultrasonic antifriction. The model was validated by comparing the calculated thermal cycles and the thermo-mechanically affected zone with the experimental measurements.http://www.sciencedirect.com/science/article/pii/S2238785422014594Friction stir weldingUltrasonic vibrationUltrasonic line sourceHeat generationMaterial flowUltrasonic antifriction
spellingShingle Guanlan Zhang
ChuanSong Wu
Jinqiang Gao
Ultrasonic line source and its coupling with the tool induced heat generation and material flow in friction stir welding
Journal of Materials Research and Technology
Friction stir welding
Ultrasonic vibration
Ultrasonic line source
Heat generation
Material flow
Ultrasonic antifriction
title Ultrasonic line source and its coupling with the tool induced heat generation and material flow in friction stir welding
title_full Ultrasonic line source and its coupling with the tool induced heat generation and material flow in friction stir welding
title_fullStr Ultrasonic line source and its coupling with the tool induced heat generation and material flow in friction stir welding
title_full_unstemmed Ultrasonic line source and its coupling with the tool induced heat generation and material flow in friction stir welding
title_short Ultrasonic line source and its coupling with the tool induced heat generation and material flow in friction stir welding
title_sort ultrasonic line source and its coupling with the tool induced heat generation and material flow in friction stir welding
topic Friction stir welding
Ultrasonic vibration
Ultrasonic line source
Heat generation
Material flow
Ultrasonic antifriction
url http://www.sciencedirect.com/science/article/pii/S2238785422014594
work_keys_str_mv AT guanlanzhang ultrasoniclinesourceanditscouplingwiththetoolinducedheatgenerationandmaterialflowinfrictionstirwelding
AT chuansongwu ultrasoniclinesourceanditscouplingwiththetoolinducedheatgenerationandmaterialflowinfrictionstirwelding
AT jinqianggao ultrasoniclinesourceanditscouplingwiththetoolinducedheatgenerationandmaterialflowinfrictionstirwelding