0000000000020618
AUTHOR
Anthony P. Reynolds
Evaluation of Residual Stresses During Fatigue Test in an FSW Joint
At present, friction stir welding (FSW) represents one of the most interesting techniques in the field of welding. The process is has been implemented in industrial practice for joining aluminium alloys, while the welding of the titanium alloy and the steels is still primarily in a developmental stage.
Bonding prediction in friction stir consolidation of aluminum alloys: A preliminary study
Friction Stir Consolidation (FSC) is a solid-state process that results in consolidation of metal powders or chips producing solid billet through severe plastic deformation and the solid-state bonding phenomena. This process can be used both for primary production and for metal scrap recycling. During the FSC process, a rotating die is plunged into a hollow chamber containing the finely divided, unconsolidated material to be processed. In this paper, a FEM numerical model for the prediction of the quality of the consolidated billet is presented. In particular, a dedicated bonding criterion that takes into account the peculiar process mechanics of this innovative technology is proposed.
Friction stir extrusion to recycle aluminum alloys scraps: Energy efficiency characterization
Abstract Solid state recycling refers to a group of processes allowing direct recycling of metals scraps into semi-finished product. Their main advantage lies in avoiding the molten state of the material which badly affects the environmental performance of the conventional (remelting based) recycling routes. It is expected that such process category would lower the environmental performance of metals recycling. In this paper, the friction stir extrusion process for aluminum alloy AA 2050 wire production is analyzed under the primary energy demand perspective. The process electrical energy demand is quantified with varying process parameters. An empirical modelling approach was applied and a…
Influence of processing parameters and initial temper on Friction Stir Extrusion of 2050 aluminum alloy
Abstract Friction Stir Extrusion is an innovative production technology that enables direct wire production via consolidation and extrusion of metal chips or solid billets. During the process, a rotating die is plunged into a cylindrical chamber containing the material to be extruded. The stirring action of the tool produces plastic flow in the extrusion chamber, densifying and heating the charge so that finally, fully dense rods are extruded. Experiments have been carried out in order to investigate the influence of process parameters and initial temper of the base material on the process variables and on the extrudates’ mechanical properties.
Process mechanics in Friction Stir Extrusion of magnesium alloys chips through experiments and numerical simulation
Abstract Friction Stir Extrusion (FSE) is a novel process designed to directly recycle machining chips. An experimental campaign was carried out on AZ31 milling chips using variations in extrusion ratio, force and tool rotation rate. The process mechanics were studied and correlated to the material flow, which was elucidated through use of a copper marker. A 3D, Lagrangian, thermo-mechanically coupled dedicated numerical model was set up and validated through temperature measurements. The combination of experimental and numerical results permitted to reconstruct the complex 3D material flow induced by tool rotation and plunge into the extrusion billet chamber.
Friction stir consolidation of aluminum machining chips
Friction stir consolidation (FSC) is a solid-phase manufacturing process that consolidates metal powder, chips, or scraps into solid blocks via severe plastic deformation and solid state welding. It has the potential to be a more economical and âgreenâ process to recycle metal waste. In this study, solid discs were made from AA6061 aluminum alloy machining chips by FSC. The progression of the process was revealed by analyzing the motion of the tool, consolidating force, power history, and macro/microstructure of discs produced from a series of partial consolidation experiments. A bowl-shaped recrystallized zone in the vertical cross-sections of the disc products was observed and conside…
Fatigue crack growth in 2024-T351 Friction Stir Welded Joints: longitudinal residual stresses and microstructural effects
Abstract The role of longitudinal residual stress on propagation of fatigue cracks was examined in friction stir welds produced in 2024-T351 aluminum alloy. Fatigue crack growth rate was obtained through constant Δ K Iapp tests for notches at different distances from the weld centerline. Subsequently, crack growth was correlated to weld residual stress measured by the cut-compliance method. It was found that residual stresses correspond to low crack growth rates outside the weld zone during fatigue loading. Once in the weld zone, the crack growth was affected by microstructural and hardness changes. Furthermore, weld residual stresses were mechanically relieved and effects on crack propagat…
Residual Stress Effects on Fatigue Crack Growth in Ti-6Al-4V Friction Stir Welds
Recent studies have illustrated a predominant role of the residual stress on the fatigue crack growth in friction stir welded joints. In this study, the role of the residual stress on the propagation of fatigue cracks orthogonal to the weld direction in a friction stir welded Ti-6Al-4V joint was investigated. A numerical prediction of the fatigue crack growth rate in the presence of the residual stresses was carried out using AFGROW software; reasonable correspondence between the predictions and the experimental results were observed when the effects of residual stress were included in the simulation.