Comparison of the Difference in Temperature Distribution on the Surface of Two Aluminum Alloys Welded by Friction Stir Welding in Different Regions at Different Linear and Rotational Speeds
Keywords:
AA2024-O, travel speed, ANSYS 15.0, rotational speed, friction stir welding, AA7075-T6
Abstract
Friction stir welding is a modern process that is used commercially on a large scale in various industries and in many countries to connect materials together without reaching the melting point of the metal during the welding process, so it is called the solid-state welding process.
In this research, a three-dimensional mathematical model was designed for friction stir welding of aluminium alloys (AA7075-T6 & AA2024-O) with dimensions (100 x 100 x 6 mm), using (ANSYS 15.0) program to compare the results of temperature distribution with distance from the welding centre to the end of the welded piece, as well as the temperature distribution from the beginning of the welding process to its end, using different rotational speeds (900, 1050, 1200 rpm) and different linear speeds (20, 40, 60, 100 mm/min). In the beginning, the rotational speed was fixed and the linear speed was made variable, and then the linear speed was fixed and the rotational speed was changed.
The experimental results showed that the increase in the rotation speed of the welding tool leads to an increase in the temperatures on the surfaces of the models that were welded by the friction stir welding method. Among the other results obtained, it was found that the increase in the traveling speed of the trolley carrying the models when the stir welding process decreases the temperatures on the surface of the models when the welding process is performed. We note the convergence of the theoretical results with the applied results.
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References
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[2]. Takashi Nakamura, Toshiyuki Obikawa, Eitaro Yukutake, Satoru Ueda, Itaru Nishizaki, Tool Temperature and Process Modeling of Friction Stir Welding, Modern Mechanical Engineering, 8, p. 78-94, 2018.
[3]. Masoud Jabbari, Effect of the Preheating Temperature on Process Time in Friction Stir Welding of Al 6061-T6, Journal of Engineering, p. 1-5, 2013.
[4]. Silva A. C. F., De Backer J., Bolmsjö G., Temperature measurements during friction stir welding, Int J Adv Manuf Technol, 88, p. 2899-2908, 2017.
[5]. Oussama Mimouni, Riad Badji, Mohamed Hadji, Afia Kouadri-David, Hamel Rachid, Nabil Chekroun, Numerical Simulation of Temperature Distribution and Material Flow During Friction Stir Welding 2017A Aluminum Alloys, MATEC Web of Conferences, 80, p. 1-8, 2016.
[6]. Iordache Monica, Nitu Eduard, Badulescu Claudiu, Iacomi Doina, Botila Lia, Radu Bogdan, Evaluation of Thermal Distribution in Friction Stir Welding on Dissimilar Materials (Cu-Al) Using Infrared Thermography and Numerical Simulation. Trans Tech Publications, 1138, p. 113-118, 2016.
[7]. Padmanaban R., Ratna Kishore V., Balusamyc V., Numerical Simulation of Temperature Distribution and Material Flow During Friction Stir Welding of Dissimilar Aluminum Alloys, Procedia Engineering, 97, p. 854-863, 2014.
[9]. Dan Birsan, Danut Iordachescu, Jose Luis Ocana, Pedro Vilaca, Fem model for friction stir welding of aluminum, The Annals of “Dunarea de Jos” University of Galati Fascicle XII, Welding Equipment and Technology, Year XIX, ISSN 1221-4639, 2008.
[10]. Peel M. J., Steuw Er A., Withers P. J., Dickerson T., Shi Q., Shercliff H., Dissimilar Friction Stir Welds in Aa5083-Aa6082, Metallurgical and Materials Transactions A, 37, p. 2183-2193, 2016.
[11]. Yuh J. Chao, Qi X., Tang W., Heat Transfer in Friction Stir Welding-Experimental and Numerical Studies, Journal of Manufacturing Science and Engineering, 125, p. 138-145, 2003.
[12]. Shabbir Memon, Jacek Tomk ów, Hesamoddin Aghajani Derazkola, Thermo-Mechanical Simulation of Underwater Friction Stir Welding of Low Carbon Steel. Materials, 14, p. 1-17, 2021.
[13]. Bindu M. D., Tide P. S., Bhasi A. B., Numerical Studies on Temperature and Material Flow During Friction Stir Welding using Different Tool Pin Profiles, Journal of Advanced Research in Fluid Mechanics and Thermal Sciences, 83, p. 91-104, 2021.
[14]. Vishwanath M. M., Lakshamanaswamy N., Ramesh G. K., Numerical Simulation of Heat Transfer Behavior of Dissimilar Aa5052-Aa6061 Plates in Fiction Stir Welding: An Experimental Validation, Journal of Mechanical Engineering, 2019, 69: pp. 159 – 170.
[15]. En-zhi Gao, Xing-xing Zhang, Chun-zhong Liu, Zong-yi Ma, Numerical simulations on material flow behaviors in whole process of friction stir welding, Trans. Nonferrous Met. Soc. China, 28, p. 2324-2334, 2018.
[16]. Anton Naumov, Evgenii Rylkov, Pavel Polyakov, Fedor Isupov, Andrey Rudskoy, Jong-Ning Aoh, Anatoly Popovich, Oleg Panchenko, Effect of Different Tool Probe Profiles on Material Flow of Al–Mg–Cu Alloy Joined by Friction Stir Welding, Materials, 14, p. 1-14, 2021.
[17]. Amir Ghiasvand, Mahdi Kazemi, Maziar Mahdipour Jalilian, Hossein Ahmadi Rashid, Effects of tool offset, pin offset, and alloys position on maximum temperature in dissimilar FSW of AA6061 and AA5086, International Journal of Mechanical and Materials Engineering, 15, 6, p. 1-14, 2020.
[18]. Vermaa S., Meenua, Misra J. P., Study on temperature distribution during Friction Stir Welding of 6082 aluminum alloy, Materials Today, 4, p. 1350-1356, 2017.
[19]. Karash E. T. B., Yassen S. R., Kassim M. T. E., Effect of friction stir welding parameters on the impact energy toughness of the 6061-t6 aluminum alloys, Annals of “Dunarea de Jos” University, Fascicle XII ISSN 1221-4639 Welding Equipment and Technology, vol. 29, p. 27-32, 2018.
[20]. Abdul Arif, Chetan Swaroop, Pandey K. N., Temperature Validation for Friction Stir Welding (Fsw) of Dissimilar Aluminum Alloys, Proceedings of International Conference on Advances in Mechanical Engineering, p. 1-10, 2013.
[21]. Birsan D., Scutelnicu E., Modelling of thermo-mechanical effects generated by friction spot stir welding process, Annals of “Dunarea de Jos” University, Fascicle XII ISSN 1221-4639, Welding Equipment and Technology, vol. 25, p. 29-34, 2014.
[22]. Bušić M., Kožuh Z., Klobčar D., Influence of the tool travel speed on friction stir processing of aluminum alloy AlCu4Mg1, Annals of “Dunarea de Jos” University, Fascicle XII, ISSN 1221-4639, Welding Equipment and Technology, vol. 28, p. 11-14, 2017.
[23]. Cole E. G., Fehrenbacher A., Duffie N. A., Zinn M. R., Pfefferkorn F. E., Ferrier N. J., Weld temperature effects during friction stir welding of dissimilar aluminum alloys 6061-t6 and 7075-t6, Int J Adv Manuf Technol, 71, p. 643-652, 2014.
[23]. Birsan D., Scutelnicu E., Stan F., Hardness of friction stir welded joints of AA-6061-t6 aluminum alloy, Annals of “Dunarea de Jos” University of Galati, Fascicle XII, Welding equipment and technology, ISSN 1221-4639, vol. 21, 2010.
[24]. Nageeb Salman Abtan, Ataalah Hussain Jassim, Mustafa Shakir Marmoos, Study on the Effects of Rotational and Transverse Speed on Temperature Distribution through Friction Stir Welding of AA2024- O Aluminium Alloy, CFD Letters, 1, p. 55-69, 2019.
[25]. Kareem N. Salloomi, Furat I. Hussein, Sanaa N. M. Al-Sumaidae, Temperature and Stress Evaluation during Three Different Phases of Friction Stir Welding of AA 7075-T651 Alloy, Hindawi, p. 1-11, 2020.
[26]. Karash E. T., Ali H. M., Hamid A. F., Mathematical Model for the Temperature Distribution on The Surface of Two Aluminum Alloys Welded by Friction Stir Welding, Annals of “Dunarea de Jos” University of Galati Fascicle XII, Welding equipment and technology, ISSN 1221-4639, vol. 23, 2022.
[27]. Emad Toma Karash, Jamal Nayief Sultan, Majid Khaleel Najem, Amenah Faris Hamid, Comparison of the Influence of Temperature Change Distribution of Three Surface Regions on the Hardness of Two Dissimilar Aluminum Alloys Welded by Friction Stir Welding, International Journal of Heat and Technology, vol. 40, no. 4, p. 1013-1023, August, 2022.
[28]. Emad T. B. K., Saeed R. Y., Mohammed T. E. Q., The Effect of the Cutting Depth of the Tool Friction Stir Process on the Mechanical Properties and Microstructures of Aluminum Alloy 6061-T6, American Journal of Mechanics and Applications, 3(5), p. 33-41, 2015.
[29]. Matweb, Your Source for Materials Information, https://www.matweb.com, 2000.
[30]. Mishra R., Murray S., Mahoney W., Friction Stir Welding and Processing, ASM International, USA, 2007.
[31]. ***, ASTM E 3 – 01, Standard Guide for Preparation of Metallographic Specimens, USA, 2001.
[32]. ***, ASM Aerospace Specifications Metals Inc. - retrieved 18 September 2019.
[33]. ***, Alcoa 2024 data sheet Archived 2006-08-27 at the Way back Machine (pdf), accessed October 13, 2006.
Published
2024-03-15
How to Cite
1.
KARASH ET, HAMID AF. Comparison of the Difference in Temperature Distribution on the Surface of Two Aluminum Alloys Welded by Friction Stir Welding in Different Regions at Different Linear and Rotational Speeds. The Annals of “Dunarea de Jos” University of Galati. Fascicle IX, Metallurgy and Materials Science [Internet]. 15Mar.2024 [cited 21Dec.2024];47(1):25-6. Available from: https://gup.ugal.ro/ugaljournals/index.php/mms/article/view/7013
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