Search results for "welding"
showing 10 items of 317 documents
Influence of distinct tool pin geometries on aluminum 8090 FSW joint properties
2023
Abstract. Aluminum Lithium alloys are recuperating substantial interest from automotive and aerospace industries owing to their extraordinary specific strength as compared to conventional aluminum (2xxx, 6xxx, and 7xxx) alloys. The goal of the present investigation is to study AA 8090 joints produced with the unique solid-state welding technique friction stir welding (FSW). Tool pin profile induces remarkable influence on friction and further plastic deformation during FSW. Therefrom, the influences of three distinct but constant dynamic area conditioned tool pin geometries namely, square trapezoidal, hexagonal trapezoidal, and threaded taper on the resulting material flow patterns, mechani…
Finite Element Studies On Friction Stir Welding Processes of Tailored Blanks
2008
Although friction stir welding (FSW) has been successfully used to join materials that are difficult-to-weld or unweldable by fusion welding methods, it is still in its early development stage and, therefore, its potential has not been fully exploited yet. FSW appears to be a very promising process for tailor-welded blanks to overcome the difficulties encountered in traditional fusion welding processes for obtaining a sound welding with good nugget integrity. In this paper the friction stir welding process for tailored blanks of aluminum alloy is investigated through a FEM developed by the authors. In particular FSW for sheets with different thicknesses is studied. For each setup a differen…
Influence of material characteristics on plastomechanics of the fsw process for T-joints
2009
Abstract The potential of friction stir welding (FSW) has thoroughly been investigated by several authors, however their focus has primarily been on butt joints. T-joints are of paramount interest for transportation industries especially due to their capacity to straighten panels. Welding of T-joints is very challenging due to thin walls, poor location of the rib–web interface and the requirements for corner-fillets. This paper investigates FSW of T-joints of two popular aluminum alloys, i.e. 2024-T4 and 6082-T6, and the role played by the material characteristics on joining. First, an experimental study is carried out with specially designed fixture to determine the effect of process condi…
Modeling of the Plastic Characteristics of AA6082 for the Friction Stir Welding Process
2015
Focus of this paper is to model the plastic forming behavior of AA6082, in order to develop the numerical FE analysis of the friction stir welding processes and the simulation of subsequent forming processes. During the friction stir welding process, the temperatures reached are until 500 °C and have a fundamental role for the correct performance of the process so the material data has to show a temperature dependency. Because of the tool rotation a strain rate sensitivity of the material has to be respected as well. In this context, the general material characteristics of AA6082 were first identified for different stress states. For the uniaxial state the standard PuD-Al used in the automo…
FEM based prediction of phase transformations during Friction Stir Welding of Ti6Al4V titanium alloy
2013
Abstract Friction Stir Welding (FSW) is a solid state welding process patented in 1991 by TWI; initially adopted to weld aluminum alloys, it is now being successfully used also for high resistant materials. Welding of titanium alloys by traditional fusion welding techniques presents several difficulties due to high material reactivity with oxygen, hydrogen, and nitrogen with consequent embrittlement of the joint. In this way FSW represents a cost effective and high quality solution. The final mechanical properties of the joints are strictly connected to the microstructural evolutions, in terms of phase change, occurring during the process. In the paper a 3D FEM model of the FSW welding proc…
An Innovative Friction Stir Welding Based Technique to Produce Dissimilar Light Alloys to Thermoplastic Matrix Composite Joints
2016
Abstract Aluminum sheets can be joined to composite materials with different techniques. Each of them has advantages and weak points over the others. In literature, new techniques and patents are continuously developed to overcome these difficulties. In the paper a new Friction Stir Welding based approach is proposed to mechanically join AA6082-T6 to self-reinforced polypropylene. The aluminum sheet is pre-holed along both the sides of the weld line. A pinless tool generates the heat and pressure needed to activate back-extrusion of the composite. Joints have been produced with varying hole diameter and pitch. The mechanical resistance of the joint has been evaluated and the different failu…
Laser Welding - Suitable for Vascular Anastomosis?
1994
Carotid arteries of 21 piglets were transsected and reanastomosed either by laser welding (Neodym:YAG laser) or by conventional suture anastomosis. Histological specimens of the anastomoses obtained 2 to 32 days after the operation showed less foreign body reaction and intimal hyperplasia after laser welding than after suturing. There was, however, no significant difference when comparing occurrence of thrombosis, patency rate, or growth of the anastomosis in growing animals. Neither our study nor a review of the literature of laser-assisted vascular anastomosis in microvessels and large arteries up to 5 mm diameter could establish a definite clinical application for laser welding in vascul…
On the thermo-mechanical loads and the resultant residual stresses in friction stir processing operations
2008
In friction stir welding and processing both a thermal flux and a mechanical action are exerted on the material determining metallurgical evolutions, changes in the mechanical behaviour and a complex residual stress state. In the paper, the metallurgical changes are examined through numerical simulation and experiments to highlight and distinguish the effects of thermal and mechanical loadings. A particular focus is made on the residual stresses generated during the stir processing of AA7075-T6 aluminium blanks. The predictions of FE model are validated by experimental measurements. Lastly, this paper presents an in-process quenching of the processed blanks for improved mechanical propertie…
Design of Numerical Simulations of Linear Friction Welding Processes: Issues and Difficulties
2015
In this paper, a critical analysis of the technical difficulties and numerical issues in running simulations of linear friction welding processes is carried out. The focus of the paper is the comparison of different modeling strategies of a numerical analysis for the LFW process of Ti-6Al-4V titanium alloy, for which the thermal aspect strongly influences the mechanical behavior due to the phase transformation, taking place over a definite range of temperature. A 3D simulation campaign, conducted using the FEA code DEFORMTM, was considered in order to show advantages and disadvantages of each approach, including the most critic limitations and complexity in a correct simulation design using…
Numerical Simulation of Friction Stir Welding by Natural Element Methods
2008
In this work we address the problem of numerically simulating the Friction Stir Welding process. Due to the special characteristics of this welding method (i.e., high speed of the rotating pin, very large deformations, etc.) finite element methods (FEM) encounter several difficulties. While Lagrangian simulations suffer from mesh distortion, Eulerian or Arbitrary Lagrangian Eulerian (ALE) ones still have difficulties due to the treatment of convective terms, the treatment of the advancing pin, and many others. Meshless methods somewhat alleviate these problems, allowing for an updated Lagrangian framework in the simulation. Accuracy is not affected by mesh distortion (and hence the name mes…