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Advanced in Modeling and Simulation in FSW(Friction Stir Welding)
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Advanced in Modeling and Simulation in FSW(Friction Stir Welding)

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Materials Simulation and Design".

Deadline for manuscript submissions: closed (20 January 2023) | Viewed by 3362

Special Issue Editor

Dr. Hamed Aghajani Derazkola

E-Mail Website
Guest Editor
Department of Mechanics, Design and Industrial Management, University of Deusto, 48007 Bilbao, Spain
Interests: finite element analysis; monte carlo modelling; cellular automaton modelling; computational fluid dynamic modelling; solid-state joining; solid-state additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Despite scientific and practical advances in friction stir welding (FSW), many issues in the FSW field are still not well understood. Thermo-mechanical (TM) phenomena during the FSW process are one of this field's industrial and research interests. Various aspects of TM phenomena during the FSP process are nearly impossible to monitor and fully understand in experimental studies. One of the best solutions to understanding TM phenomena is modeling and simulation methods. Heat generation, stress analysis, heat transfer, strain, strain rate, phase transformations, and microstructure changes are examples of simulation results. The simulation and modeling results make it easier to understand TM phenomena occurring during FSW.

Therefore, this Special Issue aims to consider research focusing on TM phenomena simulation, modeling, and computational methods during FSW. The modeling and simulation of similar and dissimilar FSW joints of all metallic materials from atomistic to macroscopic length scales (structure–property relationships) are welcome. Mathematical, solid base, and fluid dynamic base simulation would be attractive. Constitutive, Monte Carlo, and cellular automaton methods for microstructure modeling with verification are attractive as well. In this Special Issue the Guest Editors will prioritize papers addressing the utilization of various numerical methods to simulate TM phenomena at advanced FSW processes, such as laser-assisted FSW, electrically assisted FSW, ultrasonic-assisted FSW, underwater FSW, and rapid-cooling FSW processes.

Dr. Hamed Aghajani Derazkola
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • friction stir welding
  • thermo-mechanical phenomena simulations
  • material modeling in FSW
  • FSW joining mechanism
  • similar joint
  • dissimilar joint
  • laser-assisted FSW
  • electrically assisted FSW
  • ultrasonic-assisted FSW
  • underwater FSW
  • rapid-cooling FSW

Published Papers (2 papers)

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Research

20 pages, 13506 KiB  
Article
Material Defects in Friction Stir Welding through Thermo–Mechanical Simulation: Dissimilar Materials with Tool Wear Consideration
by Debtanay Das, Swarup Bag, Sukhomay Pal and Abhay Sharma
Materials 2023, 16(1), 301; https://doi.org/10.3390/ma16010301 - 28 Dec 2022
Cited by 8 | Viewed by 1651
Abstract
Despite the remarkable capabilities of friction stir welding (FSW) in joining dissimilar materials, the numerical simulation of FSW is predominantly limited to the joining of similar materials. The material mixing and defects’ prediction in FSW of dissimilar materials through numerical simulation have not [...] Read more.
Despite the remarkable capabilities of friction stir welding (FSW) in joining dissimilar materials, the numerical simulation of FSW is predominantly limited to the joining of similar materials. The material mixing and defects’ prediction in FSW of dissimilar materials through numerical simulation have not been thoroughly studied. The role of progressive tool wear is another aspect of practical importance that has not received due consideration in numerical simulation. As such, we contribute to the body of knowledge with a numerical study of FSW of dissimilar materials in the context of defect prediction and tool wear. We numerically simulated material mixing and defects (surface and subsurface tunnel, exit hole, and flash formation) using a coupled Eulerian–Lagrangian approach. The model predictions are validated with the experimental results on FSW of the candidate pair AA6061 and AZ31B. The influence of tool wear on tool dimensions is experimentally investigated for several sets of tool rotations and traverse speeds and incorporated in the numerical simulation to predict the weld defects. The developed model successfully predicted subsurface tunnel defects, surface tunnels, excessive flash formations, and exit holes with a maximum deviation of 1.2 mm. The simulation revealed the substantial impact of the plate position, on either the advancing or retreating side, on the defect formation; for instance, when AZ31B was placed on the AS, the surface tunnel reached about 50% of the workpiece thickness. The numerical model successfully captured defect formation due to the wear-induced changes in tool dimensions, e.g., the pin length decreased up to 30% after welding at higher tool rotations and traverse speeds, leading to surface tunnel defects. Full article
(This article belongs to the Special Issue Advanced in Modeling and Simulation in FSW(Friction Stir Welding))
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14 pages, 5515 KiB  
Article
Effects of Noncontact Shoulder Tool Velocities on Friction Stir Joining of Polyamide 6 (PA6)
by Raheem Al-Sabur, Hassanein I. Khalaf, Aleksandra Świerczyńska, Grzegorz Rogalski and Hesamoddin Aghajani Derazkola
Materials 2022, 15(12), 4214; https://doi.org/10.3390/ma15124214 - 14 Jun 2022
Cited by 11 | Viewed by 1266
Abstract
In this study, the effects of the traverse and rotational velocities of the noncontact shoulder tool on the heat generation and heated flux during the friction stir joining of high-density polyamide 6 (PA6) polymer were investigated. The computational fluid dynamics (CFD) method was [...] Read more.
In this study, the effects of the traverse and rotational velocities of the noncontact shoulder tool on the heat generation and heated flux during the friction stir joining of high-density polyamide 6 (PA6) polymer were investigated. The computational fluid dynamics (CFD) method was employed to simulate the thermomechanical phenomena during the friction stir joining (FSJ) process of PA6. A developed model was used to consider the void formation and thermochemical properties of PA6. The surface and internal heat flow, material flow, and geometry of the joint were simulated, and an experimental study evaluated the simulation results. The simulation results indicated that the stir zone formed was smaller than regular joints with a noncontact shoulder tool. Despite the polymer’s traditional FSJ, heat generation and material flow do not differ significantly between advancing and retreating sides. On the other hand, the surface flow is not formed, and the surface temperature gradient is in a narrow line behind the tool. The material velocity increased at higher rotational speed and lower transverse velocity and in the stir zone with more giant geometry forms. The maximum generated heat was 204 °C, and the maximum material velocity was predicted at 0.44 m/s in the stir zone, achieved at 440 rpm and 40 mm/min tool velocities. Full article
(This article belongs to the Special Issue Advanced in Modeling and Simulation in FSW(Friction Stir Welding))
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