Modeling the effects of ultrasonic vibration on friction stir welding

•A model of ultrasonic vibration enhanced friction stir welding was developed.•Effects of superimposed ultrasonic vibration on heat generation, temperature profiles and material flow in FSW were quantitatively analyzed.•Ultrasonic softening plays a dominant role in UVeFSW, while the thermal effect o...

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Published in:Journal of materials processing technology 2015-08, Vol.222, p.91-102
Main Authors: Shi, L., Wu, C.S., Liu, X.C.
Format: Article
Language:English
Subjects:
Boundaries
Computational efficiency
Friction stir welding
Heat generation
Material flow
Mathematical models
Numerical simulation
Softening
Temperature distribution
Ultrasonic vibration
Welding
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description •A model of ultrasonic vibration enhanced friction stir welding was developed.•Effects of superimposed ultrasonic vibration on heat generation, temperature profiles and material flow in FSW were quantitatively analyzed.•Ultrasonic softening plays a dominant role in UVeFSW, while the thermal effect of ultrasonic vibration is insignificant.•Superimposed ultrasonic vibration in FSW can produce an enhanced plastic material flow and larger TMAZ. A mathematical model is developed to analyze the effects of superimposed ultrasonic vibration on heat generation, temperature distribution and material flow in friction stir welding process. Ultrasonic softening plays a dominant role in ultrasonic vibration enhanced friction stir welding process, while the thermal effect of ultrasonic vibration is insignificant. Superimposing ultrasonic vibration in friction stir welding process can produce an enhanced plastic material flow, increase the welding speed and welding efficiency, and also improve the weld quality by enhancing the plastic material flow near the tool. The model is validated by a comparison of the calculated thermal cycles and thermo-mechanically affected zone boundaries with the experimentally measured ones.
doi_str_mv 10.1016/j.jmatprotec.2015.03.002
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subjects Boundaries
Computational efficiency
Friction stir welding
Heat generation
Material flow
Mathematical models
Numerical simulation
Softening
Temperature distribution
Ultrasonic vibration
Welding
title Modeling the effects of ultrasonic vibration on friction stir welding
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