Coupled Eulerian-Lagrangian (CEL) Modeling of Material Flow in Dissimilar Friction Stir Welding of Aluminum Alloys

Authors

1 Arak University of Technology

2 Department of Mechanical Engineering, Arak University of Technology, Arak, Iran

Abstract

In this work, the finite element simulation of dissimilar friction stir welding process is investigated. The welded materials are AA 6061-T6 and AA 7075-T6 aluminum alloys. For this purpose, a 3D coupled thermo-mechanical finite element model is developed according to the Coupled Eulerian-Lagrangian (CEL) method. The CEL method has the advantages of both Lagrangian and Eulerian approaches, which means it can simultaneously solve the singularity in the large deformation problems and describe the physical boundary of the material accurately. In this paper, the effects of the position of the harder material (AA 7075-T6 aluminum alloy) and the tool pin profile on the temperature distribution and material flow in the weld metal and heat affected zone (HAZ) are investigated. The results show that the material velocity around the FSW tool is found to be higher using a grooved pin profile. Moreover, placing the harder material at the advancing side results in slightly lower process temperatures in comparison to the estimated temperature when the material is placed at the retreating side for all types of tool profiles. It has been proved that if the AA 7075-T6 aluminum alloy is at the advancing side, mixing happens in a thin layer below the tool shoulder, and the penetration of the harder material into the retreating side is found to be limited. In addition, good agreement between the temperature distribution obtained from the experimental measurements and numerical simulations is achieved and the accuracy of the numerical model is confirmed.         

Keywords

References

[1] Faraji, A. H; Moradi, M; Goodarzi, M; Colucci, P; Maletta, C. An investigation on capability of hybrid Nd:YAG laser-TIG welding technology for AA2198 Al-Li alloy, Optics and Lasers in Engineering, 96 (2017) 1–6.
[2] Moradi, M; Ghoreishi, M; Rahmani, A. Numerical and Experimental Study of Geometrical Dimensions on Laser-TIG Hybrid Welding of Stainless Steel 1.4418, Journal of Modern Processes in Manufacturing and Production, 5 (2016) 21–31.
[3] Seidel, T. U; Reynolds, A. P. Two-dimensional friction stir welding process model based on fluid mechanics. Sci. Technol. Weld. Join. 8 (2003) 175–183.
[4] Ulysse, P. Three-dimensional modeling of the friction stir-welding process. Int. J. Mach. Tools Manuf. 42 (2002) 1549–1557.
[5] Colegrove, P. A; Shercliff, H. R. Development of the Trivex friction stir welding tool: Part II-3-Dimensional flow modelling. Sci. Technol. Weld. Join, 9 (2004) 352–361.
[6] Colegrove, P. A; Shercliff, H. R. 3-Dimensional CFD modelling of flow round a threaded friction stir welding tool profile. J. Mater. Process. Technol, 169 (2005) 320–327.
[7] Long, T; Reynolds, A. P. Parametric studies of friction stir welding by commercial fluid dynamics simulation. Sci. Technol. Weld. Join, 11 (2013) 200–208.
[8] Carlone, P; Palazzo, G. S. Influence of process parameters on microstructure and mechanical properties in AA2024-T3 friction stir welding. Metall. Microstruct. Anal, 2 (2013) 213–222.
[9] Deng, X; Xu, S. Two-dimensional finite element simulation of material flow in the friction stir welding process. J. Manuf. Process, 6 (2004) 125–133.
[10] Schmidt, H; Hattel, J. A local model for the thermomechanical conditions in friction stir welding. Model. Simul. Mater. Sci. Eng, 13 (2005) 77–93.
[11] Guerdoux, S; Fourment, L. A 3D numerical simulation of different phases of friction stir welding. Model. Simul. Mater. Sci. Eng, 17 (2009) 075001.
[12] Buffa, G; Hua, J; Shivpuri, R; Fratini, L. Design of the friction stir welding tool using the continuum based FEM model. Mater. Sci. Eng. A, 419 (2006) 381–388.
[13] Assidi, M; Fourment, L. Accurate 3D friction stir welding simulation tool based on friction model calibration. Int. J. Mater. Form, 2 (2009) 327–330.
[14] Dialami, N; Chiumenti, M; Cervera, M; de Saracibar, C. A. An apropos kinematic framework for the numerical modelling of Friction Stir Welding. Comput. Struct, 117 (2013) 48–57.
[15] Al-Badour, F; Merah, N; Shuaib, A; Bazoune, A. Coupled Eulerian Lagrangian finite element modeling of friction stir welding processes. J. Mater. Process. Technol. 213(8) (2013) 1433–1439.
[16] Brar, N.S; Joshi, V.S; Harris, B.W. Constitutive model constants for Al7075-T651 and Al7075-T6, AIP Conference Proceedings, Vol, 1195, (2009) 945-948.
[17] Akram, S; Jaffery, S. H. I; Khan, M; Fahad, M; Mubashar, A; Ali, L. Numerical and experimental investigation of Johnson–Cook material models for aluminum (Al 6061-T6) alloy using orthogonal machining approach. Adv. Mech. Eng, 10(9) (2018) 1-14.
[18] Thimmaraju, P. K; Arakanti, K; Mohan Reddy, G. Ch. Influence of Tool Geometry on Material Flow Pattern in Friction Stir Welding Process. Int. J. Theor. App. Mech. 12 (2017) 445–458.
[19] Jamshidi  Aval, H; Serajzadeh, S; Kokabi, A. H. Evolution  of  microstructures  and  mechanical  properties  in  similar  and  dissimilar friction  stir  welding  of  AA5086  and  AA6061. Mat. Sci. Eng. A, 528 (2011) 8071– 8083.
[20] Shivkumar, S; Ricci, S; Apelian, D. Production and Electrolysis of Light Metals, Pergamon, Halifax, (1989) 173–182.
[21] Shivkumar, S; Ricci, S; Apelian, D. Effect of solution treatment parameters on tensile properties of cast aluminum alloys, J. Heat Treating, 8 (1990) 63–70.
[22] Brett, S; Doherty, R. D. Loss of solute at the fracture surface in fatigued aluminium precipitation-hardened alloys, Mater. Sci. Eng, 32 (1978) 255–265.
[23] Lee W. B; Yeon Y. M; Jung S. B. The mechanical properties related to the dominant microstructure in the weld zone of dissimilar formed Al alloy joints by friction stir welding. J Mater Sci, 38 (2003) 4183– 4191.
Iranian Journal of Materials Forming
Volume 6, Issue 2
October 2019
Pages 10-19

Files

Share

How to cite

Statistics