A Finite Element Model to Simulate Defect Formation during Friction Stir Welding
Abstract
:1. Introduction
2. Material and Experimentation
3. Model Description
3.1. Governing Equations
3.2. Geometrical Model and Mesh Generation
3.3. Heat Generation Model
3.4. Boundary Conditions
3.4.1. Thermal Boundary Conditions
3.4.2. Velocity Boundary Conditions
3.5. Material Model
4. FE Results and Discussion
4.1. Verification of FE Model
4.2. Effect of Welding Parameters
4.3. Effect of Tool Pin Profile
5. Conclusions
- The model can predict the plasticized zone shape and the presence of void in the weld quite accurately. However, the void size is overestimated.
- The void size is directly affected by welding parameters. Welding at low welding speed or high tool rotational speed could produce a smaller void.
- Compared with a smooth tool pin, a featured tool pin can enhance plastic flow in the weld, which contributes to reducing defect size and achieving defect-free weldment.
Acknowledgments
Author Contributions
Conflicts of Interest
References
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T [°C] | ρ [kg m−3] | E [GPa] | v | α [10−6·°C−1] | CP [J kg−1·°C−1] | λ [W m−1·°C−1] |
---|---|---|---|---|---|---|
25 | 2690 | 66.94 | 0.33 | 23.5 | 945 | 167 |
100 | 2690 | 63.21 | 0.334 | 24.6 | 978 | 177 |
149 | 2670 | 61.32 | 0.335 | 25.7 | 1000 | 184 |
204 | 2660 | 56.8 | 0.336 | 26.6 | 1030 | 192 |
260 | 2660 | 51.15 | 0.338 | 27.6 | 1052 | 201 |
316 | 2630 | 47.17 | 0.36 | 28.5 | 1080 | 207 |
371 | 2630 | 43.51 | 0.4 | 29.6 | 1100 | 217 |
427 | 2600 | 28.77 | 0.41 | 30.7 | 1130 | 223 |
482 | - | 20.2 | 0.42 | - | 1276 | - |
A [MPa] | B [MPa] | C | n | m | Tref [°C] | Tmelt [°C] | |
---|---|---|---|---|---|---|---|
324 | 114 | 0.002 | 0.42 | 1.34 | 24 | 583 | 1.0 |
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Zhu, Z.; Wang, M.; Zhang, H.; Zhang, X.; Yu, T.; Wu, Z. A Finite Element Model to Simulate Defect Formation during Friction Stir Welding. Metals 2017, 7, 256. https://doi.org/10.3390/met7070256
Zhu Z, Wang M, Zhang H, Zhang X, Yu T, Wu Z. A Finite Element Model to Simulate Defect Formation during Friction Stir Welding. Metals. 2017; 7(7):256. https://doi.org/10.3390/met7070256
Chicago/Turabian StyleZhu, Zhi, Min Wang, Huijie Zhang, Xiao Zhang, Tao Yu, and Zhenqiang Wu. 2017. "A Finite Element Model to Simulate Defect Formation during Friction Stir Welding" Metals 7, no. 7: 256. https://doi.org/10.3390/met7070256