Friction Stir Welding in Wrought and Cast Aluminum Alloys: Heat Transfer Modeling and Thermal History Analysis

Friction stir welding (FSW) is a technique that can be used for materials joining and local microstructural refinement. Owing to the solid-state character of the process, FSW has significant advantages over traditional fusion welding, including reduced part distortion and overheating. In this study,...

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Bibliographic Details
Published in:Metallurgical and materials transactions. A, Physical metallurgy and materials science Physical metallurgy and materials science, 2017-02, Vol.48 (2), p.722-734
Main Authors: Pan, Yi, Lados, Diana A.
Format: Article
Language:English
Subjects:
Aluminum alloys
Aluminum base alloys
Analysis
Characterization and Evaluation of Materials
Chemistry and Materials Science
Computer simulation
Friction
Friction stir welding
Heat generation
Heat transfer
Materials Science
Mathematical models
Metallic Materials
Nanotechnology
Structural Materials
Surfaces and Interfaces
Temperature distribution
Thin Films
Two-dimensional analysis
Welded joints
Welding
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Summary:Friction stir welding (FSW) is a technique that can be used for materials joining and local microstructural refinement. Owing to the solid-state character of the process, FSW has significant advantages over traditional fusion welding, including reduced part distortion and overheating. In this study, a novel heat transfer model was developed to predict weld temperature distributions and quantify peak temperatures under various combinations of processing parameters for different wrought and cast Al alloys. Specifically, an analytical analysis was first developed to characterize and predict heat generation rate within the weld nugget, and then a two-dimensional (2D) numerical simulation was performed to evaluate the temperature distribution in the weld cross-section and top-view planes. A further three-dimensional (3D) simulation was developed based on the heat generation analysis. The model was validated by measuring actual temperatures near the weld nugget using thermocouples, and good agreement was obtained for all studied materials and conditions.
ISSN:1073-5623
1543-1940
DOI:10.1007/s11661-016-3865-0