Version 1
: Received: 7 December 2022 / Approved: 8 December 2022 / Online: 8 December 2022 (04:42:20 CET)
How to cite:
Ansari, M.A.; Agiwal, H.; Franke, D.; Zinn, M.; Pfefferkorn, F.E.; Rudraraju, S. Numerical Investigation into the Influence of Alloy Type and Thermo-mechanics on Void Formation in Friction Stir Welding of Aluminium Alloys. Preprints2022, 2022120145. https://doi.org/10.20944/preprints202212.0145.v1
Ansari, M.A.; Agiwal, H.; Franke, D.; Zinn, M.; Pfefferkorn, F.E.; Rudraraju, S. Numerical Investigation into the Influence of Alloy Type and Thermo-mechanics on Void Formation in Friction Stir Welding of Aluminium Alloys. Preprints 2022, 2022120145. https://doi.org/10.20944/preprints202212.0145.v1
Ansari, M.A.; Agiwal, H.; Franke, D.; Zinn, M.; Pfefferkorn, F.E.; Rudraraju, S. Numerical Investigation into the Influence of Alloy Type and Thermo-mechanics on Void Formation in Friction Stir Welding of Aluminium Alloys. Preprints2022, 2022120145. https://doi.org/10.20944/preprints202212.0145.v1
APA Style
Ansari, M.A., Agiwal, H., Franke, D., Zinn, M., Pfefferkorn, F.E., & Rudraraju, S. (2022). Numerical Investigation into the Influence of Alloy Type and Thermo-mechanics on Void Formation in Friction Stir Welding of Aluminium Alloys. Preprints. https://doi.org/10.20944/preprints202212.0145.v1
Chicago/Turabian Style
Ansari, M.A., Frank E. Pfefferkorn and Shiva Rudraraju. 2022 "Numerical Investigation into the Influence of Alloy Type and Thermo-mechanics on Void Formation in Friction Stir Welding of Aluminium Alloys" Preprints. https://doi.org/10.20944/preprints202212.0145.v1
Abstract
This study employs a high-fidelity numerical framework to determine the plastic material flow patterns and temperature distributions that lead to void formation during friction stir welding (FSW), and to relate the void morphologies to the underlying alloy material properties and process conditions. Three aluminum alloys, viz., 6061-T6, 7075-T6, and 5053-H18 were investigated under varying traverse speeds. The choice of aluminum alloys enables investigation of a wide range of thermal and mechanical properties. The numerical simulations were validated using experimental observations of void morphologies in these three alloys. Temperatures, plastic strain rates, and material flow patterns are considered. The key results from this study are: (1) The predicted stir zone and void morphology are in good agreement with the experimental observations, (2) The temperature and plastic strain-rate maps in the steady-state process conditions show a strong dependency on the alloy type and traverse speeds, (3) The material velocity contours provide a good insight into the material flow in the stir zone for the FSW process conditions that result in voids as well as those that do not result in voids. The numerical model and the ensuing parametric studies presented in this work provide a framework for understanding material flow under different process conditions in aluminum alloys, and potentially in other alloys. Furthermore, the utility of the numerical model for making quantitative predictions and investigating different process parameters to reduce void formation is demonstrated.
Keywords
aluminum; finite element analysis; predictive model; numerical analysis; voids; material flow; plasticity
Subject
Engineering, Mechanical Engineering
Copyright:
This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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