Aude Simar

Effect of boundary conditions and heat source distribution on temperature distribution in friction stir welding

Abstract Welding experiments on Al-6005A have been carried out using a fully instrumented milling machine. The power input was calculated from the measured torque and forces. The thermal cycles were measured at various locations close to the weld centreline. A finite element pseudo-steady-state uncoupled thermal model was developed, taking into account the influence of the welding parameters on the power input. The distribution of the total power input between surface and volume heat sources was also studied. The measured and predicted thermal cycles are in good agreement when proper contact conditions between the workpiece and the backing plate are introduced.

Effect of rotational material flow on temperature distribution in friction stir welds

Abstract A finite element pseudosteady state thermal model takes the mechanical power as input data while distributing the total power input between surface and volume heat sources. A simple model for the material flow around the tool has been developed in order to take heat convection into account based on the shape of the thermomechanically affected zone. The model is assessed for a large number of different welding parameters. Special attention is given to the type of contact at the tool/workpiece interface, i.e. sliding, sticking or both and at the workpiece backing plate interface. The rotational material flow creates asymmetry in the temperature distribution between the two sides of the weld.

State of the art about dissimilar metal friction stir welding

ABSTRACT Friction stir welding is a rather recent welding process (patented in 1991 by Thomas et al., ‘Improvements to friction welding’ UK patent application no. 9125978.8, US Patent 5460317, 1995) that has shown great potential for welding dissimilar materials even of different metallic nature, e.g. Al to steel, Mg to steel, Al to Ti, Mg to Ti, Al to Cu, Al to Mg. This review presents the specific microstructural features and mechanical properties, in particular tensile strength, of such welds. A focus will be on the material flow and welding defects, on the intermetallic compounds, on constitutional liquation, on particularities related to dissimilar lap welding and finally on process modifications to improve dissimilar friction stir weldability.

Comparing similar and dissimilar friction stir welds of 2017–6005A aluminium alloys

Abstract Similar and dissimilar friction stir welds made of aluminium alloys 2017-T6 and 6005A-T6 are compared in terms of heat inputs, temperatures, material flow distributions and resulting local and overall tensile properties. Similar welds are systematically hotter and weaker than the dissimilar welds. Predictions of a three-dimensional finite element model of the tensile test transverse to the weldline are assessed towards local deformation fields measured by digital image correlation. Deformation systematically localises on the weakest heat affected zone, which is on the 6005A side in the dissimilar welds.

Finite Element Modelling of Friction Stir Welding of Aluminium alloy Plates - Inverse Analysis using a Genetic Algorithm

This paper presents finite element simulation results of instrumented FSW experiments on aluminium alloys 6005A-T6 and 2024-T3. The SAMCEF™ finite element code is used to perform the simulations. The FE model involves a sequential thermal-mechanical analysis and includes contact between the meshed tool, workpiece and backing plate. The model takes into account the pressure applied by the tool on the weld as well as the heat input. The heat transfers such as convection in air and contact conductance with the backing plate are modelled. For each experiment, the temperature time-histories were recorded at several locations in the workpiece. The heat input in the finite element model is identified by minimising the objective function of a constrained problem using a genetic optimisation algorithm. The objective function is the square of the difference between the experimental measurements and the numerical prediction of temperature. Finally, levels of residual stress predicted by simulation are presented.

Modelling thermal cycles and intermetallic growth during friction melt bonding of ULC steel to aluminium alloy 2024-T3

Abstract Dissimilar materials, aluminium 2024-T3 and ultralow carbon steel, have been welded by a novel process called friction melt bonding. A finite element thermal model is developed to predict temperature cycles and to estimate the fusion pool geometry and the intermetallic bonding layer thickness. The total mechanical power input in pseudo-steady state is inferred from in situ measurements at the tool torque and rotational speed. Temperature dependent properties, including the latent heat of fusion, and proper contact conditions between the welded plates and the backing plate are included. Predicted temperatures are in agreement with the measurements at various distances from the weld centreline. Molten pool geometries and intermetallic thicknesses, whose control is crucial to insure good weld mechanical performances, are also in accordance with the experimental observations.

Dissimilar Friction Stir Welding of 2014 to 6061 Aluminum Alloys

Welding cheap and ductile 6xxx Al alloys with high strength 2xxx Al alloys is desirable for instance in specific aeronautical applications. These alloys present different rheological behaviors and melting temperatures which affect the ability to produce sound dissimilar friction stir welds. Dissimilar friction stir butt welds made of 2014-T6 and 6061-T6 Al alloys were performed with various welding parameters including shifts of the tool from the initial separation between the plates to be welded and placing one alloy either on the advancing, or on the retreating side of the weld. Temperature measurements during welding, mechanical characterization (transverse tensile tests and hardness profiles) and macrographic observations were performed. Macrographies on sections perpendicular to the welding direction reveal different metal flow patterns in the weld nugget. If the 2014 alloy is placed on the advancing side of the weld, an abrupt transition between the weld nugget and the 6061 alloy is observed on macrographs leading to premature fracture in tension. Dissimilar welds are cooler on the 6061 side of the weld, i.e. the weakest side of the weld, than the corresponding 6061 similar weld, limiting the growth of the hardening precipitates. This leads thus to higher strength of the dissimilar welds. Dissimilar welds with the weld center shifted towards the 2014 alloy present lower temperatures than unshifted welds on the 6061 side of the weld, also leading to higher strength.

C Fibres - Mg Matrix Composites Produced by Squeeze Casting and Friction Stir Processing: Microstructure & Mechanical Behaviour

Mg-Al-Zn alloys have been reinforced with carbon fibres using either the liquid state process of squeeze casting (SC), or friction stir processing (FSP), a solid state process developed more recently and that appears as a promising alternative for the large-scale production of C-Mg composites. Both processes have shown their ability to produce sound composites with enhanced strength compared to the non-reinforced alloys. In SC composites, the unsized woven C fabric remains intact while in the FSP composites the sized C fabric is fragmented in short fibres, with an aspect ratio typically equal to 4, homogenously distributed in the Mg alloy matrix.

Strain Hardening and Damage in 6xxx Series Aluminum Alloy Friction Stir Welds

A friction stir weld in 6005A-T6 aluminum alloy has been prepared and analyzed by micro-hardness measurements, tensile testing and scanning electron microscopy (SEM). The locations of the various weld zones were determined by micro-hardness indentation measurements. The flow behavior of the various zones of the weld was extracted using micro-tensile specimens cut out parallel to the welding direction. The measured material properties and weld topology were then introduced in a fully coupled micro-mechanical finite element model, accounting for nucleation and growth of voids as well as void shape evolution. The model shows satisfactory preliminary results in predicting the tensile behaviour of the weld and the true strain at fracture.

On the Prediction of Hot Tearing in Al-to-Steel Welding by Friction Melt Bonding

Aluminum alloy AA6061 was welded to dual-phase steel 980 (DP980) by the friction melt bonding (FMB) process. Hot tears have been suppressed by controlling the thermomechanical cycle. In particular, the welding speed and the thermal conductivity of the backing plate have been optimized. A finite-element thermomechanical model coupled with the Rappaz–Drezet–Gremaud (RDG) criterion has been used to explain these experimental observations. The hot tear susceptibility has been reduced with large thermal gradients and with the formation of a cellular microstructure. Both effects are favored by a backing plate made of a material with high thermal conductivity, such as copper.