Numerical simulation of ultrasonic vibration-enhanced friction stir welding process of dissimilar Al/Mg alloys

A model including the acoustic plasticity and ultrasonic induced friction reduction (UiFR) effect was developed and experimentally validated for ultrasonic vibration enhanced friction stir welding (UVeFSW) of dissimilar Al/Mg alloys. It was found that the ultrasonic sound pressure and energy are str...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2022-05, Vol.120 (3-4), p.2277-2289
Main Authors: Yang, Chunliang, Wu, ChuanSong
Format: Article
Language:English
Subjects:
Aluminum base alloys
CAE) and Design
Coefficient of friction
Computer-Aided Engineering (CAD
Deformation effects
Dissimilar material joining
Dissimilar materials
Energy dissipation
Energy distribution
Engineering
Friction reduction
Friction stir welding
Heat flux
Heat generation
Industrial and Production Engineering
Magnesium
Mathematical models
Mechanical Engineering
Media Management
Original Article
Sound pressure
Ultrasonic vibration
Workpieces
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Summary:A model including the acoustic plasticity and ultrasonic induced friction reduction (UiFR) effect was developed and experimentally validated for ultrasonic vibration enhanced friction stir welding (UVeFSW) of dissimilar Al/Mg alloys. It was found that the ultrasonic sound pressure and energy are stronger at the aluminum alloy side, and the distribution of acoustic energy presents a pattern in the nugget zone. Owing to the UiFR effect, the friction coefficient at the tool-workpiece interface shown a “deformed” butterfly shape, the heat generation at the tool-workpiece interface and the viscous dissipation were reduced, and the heat flux distribution at the tool-workpiece interface shown a less “deformed” butterfly shape. The calculated results show that ultrasonic vibration enhanced the material flow and promoted the mixing and distribution of dissimilar materials.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-022-08927-5