An Experimentally Validated Thermo- Mechanical Finite Element Model for Friction Stir Welding in Carbon Steels
Solidification cracking and hydrogen cracking are some defects generated in the fusion welding of ultrahigh carbon steels. However, friction stir welding (FSW) of such steels, being a solid-state technique, has been demonstrated to alleviate such problems encountered in traditional welding. FSW include different process parameters that must be carefully defined prior processing. These parameters included but not restricted to: tool feed, tool RPM, tool geometry, tool tilt angle. These parameters form a key factor behind avoiding warm holes and voids behind the tool and in achieving a defect-free weld. More importantly, these parameters directly affect the microstructure of the weld and hence the final mechanical properties of weld. For that, 3D finite element (FE) thermo-mechanical model was developed using DEFORM 3D to simulate FSW of carbon steel. At points of interest in the joint, tracking is done for history of critical state variables such as temperature, stresses, and strain rates. Typical results found include the ability to simulate different weld zones. Simulations predictions were successfully compared to experimental FSW tests. It is believed that such a numerical model can be used to optimize FSW processing parameters to favor desirable defect free weld with better mechanical properties.
[1] T. Lienert, W. Stellwag, JR., B. Grimmett, R. Warke. 2003. Friction Stir
Welding Studies on Mild Steel. Supplement to the welding journal (1-S-
9-S)
[2] M. Guerra, C. Schmidt, J.C. McClure, L.E. Murr, A.C. Nunes, 2002.
Flow patterns during friction stir welding. Materials Characterization 49
(2003) 95- 101. Department of Metallurgical and Materials Engineering,
University of Texas at El Paso, El Paso, TX 79968-0520, USAbNASA,
Marshall Space Flight Center, Huntsville, AL, USA
[3] L. Cui, H. Fujii, N. Tsuji, K. Nogi.2007. Friction stir welding of a high
carbon steel. Scripta Materialia 56 (2007) 637-640. Joining and Welding
Research Institute, Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka
567-0047, Japan Department of Adaptive Machine Systems, Osaka
University, Suita, Osaka 565-0871, Japan
[4] R. Mishra, Z. Ma. 2005. Friction stir welding and processing. Materials
Science and Engineering R 50 (2005) 1-78Center for Friction Stir
Processing, Department of Materials Science and Engineering,
University of Missouri, Rolla, MO 65409, USA Institute of Metal
Research, Chinese Academy of Sciences, Shenyang 110016, China
[5] A. Ozekcin, H. Jin, J. Koo, N. Bangaru, R. Ayer. 2004. A
Microstructural Study of Friction Stir Welded Joints of Carbon Steels.
International Journal of Offshore and Polar Engineering.
[6] J Cho, Donald E. Boyce, P. Dawson. 2005. Modeling strain
hardening and texture evolution in friction stir welding of stainless
steel. Materials Science and Engineering A 398 (2005) 146-163. Sibley
School of Mechanical and Aerospace Engineering, Cornell University,
196 Rhodes Hall, Ithaca, NY 14853, USA
[7] H. Fujii, L. Cui, N. Tsuji ,M. Maeda, K.Nakata, K. Nogi.2006. Friction
stir welding of carbon steels. Materials Science and Engineering A 429
(2006) 50-57. Joining and Welding Research Institute, Osaka
University, 11-1 Mihogaoka, Ibaraki, Osaka 567-0047,
Japan.Department of Adaptive Machine Systems, Osaka University,
Suita, Osaka 565-0871, Japan, Center for Advanced Science and
Innovation, Osaka University, Suita, Osaka 565-0871, Japan
[8] Y. Sato, T. Nelson, C. Sterling, R. Steel, C. Pettersson. 2005.
Microstructure and mechanical properties of friction stir welded SAF
2507 super duplex stainless steel. Materials Science and Engineering A
397 (2005) 376-384. Department of Materials Processing, Graduate
School of Engineering, Tohoku University, 6-6-02 Aramaki-aza-Aoba,
Sendai 980-8579, Japan Mechanical Engineering Department, Brigham
Young University, 435 CTB, Provo, UT 84602, USA MegaStir
Technologies, 275 West 2230North, Provo, UT 84604, USA Sankvik
Materials Technology, Sandviken S-811 81, Sweden
[9] Y. Sun, Y. Konishi, M. Kamai, H. Fujii. Microstructure and mechanical
propertiesof S45C steel prepared by laser-assisted friction stir welding.
Materials and Design 47 (2013) 842-849. Joining and Welding Research
Institute, Osaka University, Japan
[10] Buffa, G., Fratini, L., and Shivpuri, R., 2007, "CDRX Modelling in
Friction Stir Welding of AA7075-T6 Aluminum Alloy: Analytical
Approaches," Journal of Materials Processing Technology, 191(1-3) pp.
356-359.
[11] H. R. Mackenzie, D., and Li, H., 2010, "Multi-Physics Simulation of
Friction Stir Welding Process," Engineering Computations (Swansea,
Wales), 27(8) pp. 967-985.
[12] Nandan, R., Prabu, B., De, A., & Debroy, T. (2007). Improving
reliability of heat transfer and materials flow calculations during friction
stir welding of dissimilar aluminum alloys. WELDING JOURNALNEWYORK-,
86(10),313.
[13] Nandan, R., Roy, G. G., Lienert, T. J., & Debroy, T. (2007). Threedimensional
heat and material flow during friction stir welding of mild
steel. Acta Materialia,55(3), 883-895.
[1] T. Lienert, W. Stellwag, JR., B. Grimmett, R. Warke. 2003. Friction Stir
Welding Studies on Mild Steel. Supplement to the welding journal (1-S-
9-S)
[2] M. Guerra, C. Schmidt, J.C. McClure, L.E. Murr, A.C. Nunes, 2002.
Flow patterns during friction stir welding. Materials Characterization 49
(2003) 95- 101. Department of Metallurgical and Materials Engineering,
University of Texas at El Paso, El Paso, TX 79968-0520, USAbNASA,
Marshall Space Flight Center, Huntsville, AL, USA
[3] L. Cui, H. Fujii, N. Tsuji, K. Nogi.2007. Friction stir welding of a high
carbon steel. Scripta Materialia 56 (2007) 637-640. Joining and Welding
Research Institute, Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka
567-0047, Japan Department of Adaptive Machine Systems, Osaka
University, Suita, Osaka 565-0871, Japan
[4] R. Mishra, Z. Ma. 2005. Friction stir welding and processing. Materials
Science and Engineering R 50 (2005) 1-78Center for Friction Stir
Processing, Department of Materials Science and Engineering,
University of Missouri, Rolla, MO 65409, USA Institute of Metal
Research, Chinese Academy of Sciences, Shenyang 110016, China
[5] A. Ozekcin, H. Jin, J. Koo, N. Bangaru, R. Ayer. 2004. A
Microstructural Study of Friction Stir Welded Joints of Carbon Steels.
International Journal of Offshore and Polar Engineering.
[6] J Cho, Donald E. Boyce, P. Dawson. 2005. Modeling strain
hardening and texture evolution in friction stir welding of stainless
steel. Materials Science and Engineering A 398 (2005) 146-163. Sibley
School of Mechanical and Aerospace Engineering, Cornell University,
196 Rhodes Hall, Ithaca, NY 14853, USA
[7] H. Fujii, L. Cui, N. Tsuji ,M. Maeda, K.Nakata, K. Nogi.2006. Friction
stir welding of carbon steels. Materials Science and Engineering A 429
(2006) 50-57. Joining and Welding Research Institute, Osaka
University, 11-1 Mihogaoka, Ibaraki, Osaka 567-0047,
Japan.Department of Adaptive Machine Systems, Osaka University,
Suita, Osaka 565-0871, Japan, Center for Advanced Science and
Innovation, Osaka University, Suita, Osaka 565-0871, Japan
[8] Y. Sato, T. Nelson, C. Sterling, R. Steel, C. Pettersson. 2005.
Microstructure and mechanical properties of friction stir welded SAF
2507 super duplex stainless steel. Materials Science and Engineering A
397 (2005) 376-384. Department of Materials Processing, Graduate
School of Engineering, Tohoku University, 6-6-02 Aramaki-aza-Aoba,
Sendai 980-8579, Japan Mechanical Engineering Department, Brigham
Young University, 435 CTB, Provo, UT 84602, USA MegaStir
Technologies, 275 West 2230North, Provo, UT 84604, USA Sankvik
Materials Technology, Sandviken S-811 81, Sweden
[9] Y. Sun, Y. Konishi, M. Kamai, H. Fujii. Microstructure and mechanical
propertiesof S45C steel prepared by laser-assisted friction stir welding.
Materials and Design 47 (2013) 842-849. Joining and Welding Research
Institute, Osaka University, Japan
[10] Buffa, G., Fratini, L., and Shivpuri, R., 2007, "CDRX Modelling in
Friction Stir Welding of AA7075-T6 Aluminum Alloy: Analytical
Approaches," Journal of Materials Processing Technology, 191(1-3) pp.
356-359.
[11] H. R. Mackenzie, D., and Li, H., 2010, "Multi-Physics Simulation of
Friction Stir Welding Process," Engineering Computations (Swansea,
Wales), 27(8) pp. 967-985.
[12] Nandan, R., Prabu, B., De, A., & Debroy, T. (2007). Improving
reliability of heat transfer and materials flow calculations during friction
stir welding of dissimilar aluminum alloys. WELDING JOURNALNEWYORK-,
86(10),313.
[13] Nandan, R., Roy, G. G., Lienert, T. J., & Debroy, T. (2007). Threedimensional
heat and material flow during friction stir welding of mild
steel. Acta Materialia,55(3), 883-895.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:52115", author = "A. H. Kheireddine and A. A. Khalil and A. H. Ammouri and G. T. Kridli and R. F. Hamade", title = "An Experimentally Validated Thermo- Mechanical Finite Element Model for Friction Stir Welding in Carbon Steels", abstract = "Solidification cracking and hydrogen cracking are some defects generated in the fusion welding of ultrahigh carbon steels. However, friction stir welding (FSW) of such steels, being a solid-state technique, has been demonstrated to alleviate such problems encountered in traditional welding. FSW include different process parameters that must be carefully defined prior processing. These parameters included but not restricted to: tool feed, tool RPM, tool geometry, tool tilt angle. These parameters form a key factor behind avoiding warm holes and voids behind the tool and in achieving a defect-free weld. More importantly, these parameters directly affect the microstructure of the weld and hence the final mechanical properties of weld. For that, 3D finite element (FE) thermo-mechanical model was developed using DEFORM 3D to simulate FSW of carbon steel. At points of interest in the joint, tracking is done for history of critical state variables such as temperature, stresses, and strain rates. Typical results found include the ability to simulate different weld zones. Simulations predictions were successfully compared to experimental FSW tests. It is believed that such a numerical model can be used to optimize FSW processing parameters to favor desirable defect free weld with better mechanical properties.
", keywords = "Carbon Steels, DEFORM 3D, FEM, Friction stir
welding.", volume = "7", number = "4", pages = "570-4", }
