A Refined Energy-Based Model for Friction-Stir Welding
Friction-stir welding has received a huge interest in the last few years. The many advantages of this promising process have led researchers to present different theoretical and experimental explanation of the process. The way to quantitatively and qualitatively control the different parameters of the friction-stir welding process has not been paved. In this study, a refined energybased model that estimates the energy generated due to friction and plastic deformation is presented. The effect of the plastic deformation at low energy levels is significant and hence a scale factor is introduced to control its effect. The predicted heat energy and the obtained maximum temperature using our model are compared to the theoretical and experimental results available in the literature and a good agreement is obtained. The model is applied to AA6000 and AA7000 series.
[1] W. M Thomas, "Friction Stir Butt Welding", International Patent
Application PCT/GB92, Patent Application GB125978.8, 1991.
[2] The Welding Institute Website: www.twi.co.uk
[3] P. Heurtier, M. J. Jones, C. Desrayaud, J. H. Driver, F. Fontheillet, and D.
Allehaux, "Mechanical and Thermal Modeling of Friction Stir Welding",
Journal of Materials Processing Technology, Vol. 171, pp. 348-357, 2006.
[4] R. S. Mishra, and Z. Y. Ma, "Friction Stir Welding and Processing",
Materials Sciences and Engineering, R 50, pp. 1-78, 2005.
[5] G. J. Bendzsak, T. H. North, and C. B. Smith, "An Experimentally 3D
Model for Friction Stir Welding", 2nd International Symposium ÔÇÿFriction Stir
Welding-, TWI Ltd., Gothenburg, Sweden, 2000.
[6] Askari, S. Silling, B. London, and M. Mahoney, "Modeling and Analysis
of Friction Stir Welding Processing", K. V. Jata, et al. (Eds.), Friction Stir
Welding and Processing, TMS, Warrendale, PA, pp. 43-54, 2001.
[7] P. Heurtier, C. Desrayaud, and F. Montheillet, "A Thermomechanical
Analysis of the Friction Stir Welding Process", Materials Science Forum,
Trans. Tech. Publications, Switzerland, pp. 1537-1542, 2002.
[8] S. Xu and X. Deng, "Two and Three Dimensional Finite Element Models
for the Friction Stir Welding Process", 4th Int. Symp. On Friction Stir
Welding, TWI Ltd., Park City, Utah, USA, 2003.
[9] P. Dong, F. Lu, J.K. Hong, and Z. Cao, "Coupled Thermomechanical
Analysis of the Friction Stir welding Process using Simplified Models",
Science Technology Welding and Joining, Vol. 6, pp. 281-287, 2001.
[10] P. Ulysse, "Three-Dimensional Modeling of Friction Stir Welding
Process", International Journal of Machine Tools and Manufacture, Vol. 42,
pp. 1549-1557, 2002.
[11] F. Palm, U. Hennebohle, V. Erofeev, E. Earpuchin, and O. Zaitzev,
"Improved Verification of FSW-Process Modeling relating to the Origin of
Material Plasticity", 4th Int. Symp. On Friction Stir Welding, TWI Ltd., Metz,
France, 2004.
[12] Hamilton, S. Dymek, and A. Sommers, "A Thermal Model of Friction
Stir Welding in Aluminum Alloys", International Journal of Machine Tools
and Manufacture, Vol. 48, pp. 1120-1130, 2008.
[13] O. Frigaard, O. Grong, and O. T. Milding, "Modeling of Heat Flow
Phenomena in Friction Stir Welding of Aluminum Alloys", Proceedings of the
7th International Conference in Joints in Aluminum, Vol. S16, 1998.
[14] P. A. Colgrove, and H. R. Shercliff, "Experimental and Numerical
Analysis of Aluminum Alloy 7075-T7351 Friction Stir Welds", Science and
Technology of Welding and Joining, Vol. 8, pp. 360-368, 2003.
[15] M. Z. Khandkar, J. A. Khan, and A. P. Reynolds, "Prediction to
Temperature Distribution and thermal History during Friction Stir Welding:
Input Torque based Model", Science and Technology of Welding and Joining,
Vol. 8, pp. 165-174, 2003.
[16] P. A. Colgrove and H. R. Shercliff, "Three-Dimensional CFD Modeling
of Flow around a Threaded Friction Stir Welding Tool Profile", Journal of
Materials Processing Technology, Vol. 169, pp. 320-327, 2005
eted from the biography.
[1] W. M Thomas, "Friction Stir Butt Welding", International Patent
Application PCT/GB92, Patent Application GB125978.8, 1991.
[2] The Welding Institute Website: www.twi.co.uk
[3] P. Heurtier, M. J. Jones, C. Desrayaud, J. H. Driver, F. Fontheillet, and D.
Allehaux, "Mechanical and Thermal Modeling of Friction Stir Welding",
Journal of Materials Processing Technology, Vol. 171, pp. 348-357, 2006.
[4] R. S. Mishra, and Z. Y. Ma, "Friction Stir Welding and Processing",
Materials Sciences and Engineering, R 50, pp. 1-78, 2005.
[5] G. J. Bendzsak, T. H. North, and C. B. Smith, "An Experimentally 3D
Model for Friction Stir Welding", 2nd International Symposium ÔÇÿFriction Stir
Welding-, TWI Ltd., Gothenburg, Sweden, 2000.
[6] Askari, S. Silling, B. London, and M. Mahoney, "Modeling and Analysis
of Friction Stir Welding Processing", K. V. Jata, et al. (Eds.), Friction Stir
Welding and Processing, TMS, Warrendale, PA, pp. 43-54, 2001.
[7] P. Heurtier, C. Desrayaud, and F. Montheillet, "A Thermomechanical
Analysis of the Friction Stir Welding Process", Materials Science Forum,
Trans. Tech. Publications, Switzerland, pp. 1537-1542, 2002.
[8] S. Xu and X. Deng, "Two and Three Dimensional Finite Element Models
for the Friction Stir Welding Process", 4th Int. Symp. On Friction Stir
Welding, TWI Ltd., Park City, Utah, USA, 2003.
[9] P. Dong, F. Lu, J.K. Hong, and Z. Cao, "Coupled Thermomechanical
Analysis of the Friction Stir welding Process using Simplified Models",
Science Technology Welding and Joining, Vol. 6, pp. 281-287, 2001.
[10] P. Ulysse, "Three-Dimensional Modeling of Friction Stir Welding
Process", International Journal of Machine Tools and Manufacture, Vol. 42,
pp. 1549-1557, 2002.
[11] F. Palm, U. Hennebohle, V. Erofeev, E. Earpuchin, and O. Zaitzev,
"Improved Verification of FSW-Process Modeling relating to the Origin of
Material Plasticity", 4th Int. Symp. On Friction Stir Welding, TWI Ltd., Metz,
France, 2004.
[12] Hamilton, S. Dymek, and A. Sommers, "A Thermal Model of Friction
Stir Welding in Aluminum Alloys", International Journal of Machine Tools
and Manufacture, Vol. 48, pp. 1120-1130, 2008.
[13] O. Frigaard, O. Grong, and O. T. Milding, "Modeling of Heat Flow
Phenomena in Friction Stir Welding of Aluminum Alloys", Proceedings of the
7th International Conference in Joints in Aluminum, Vol. S16, 1998.
[14] P. A. Colgrove, and H. R. Shercliff, "Experimental and Numerical
Analysis of Aluminum Alloy 7075-T7351 Friction Stir Welds", Science and
Technology of Welding and Joining, Vol. 8, pp. 360-368, 2003.
[15] M. Z. Khandkar, J. A. Khan, and A. P. Reynolds, "Prediction to
Temperature Distribution and thermal History during Friction Stir Welding:
Input Torque based Model", Science and Technology of Welding and Joining,
Vol. 8, pp. 165-174, 2003.
[16] P. A. Colgrove and H. R. Shercliff, "Three-Dimensional CFD Modeling
of Flow around a Threaded Friction Stir Welding Tool Profile", Journal of
Materials Processing Technology, Vol. 169, pp. 320-327, 2005
eted from the biography.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:60664", author = "Samir A. Emam and Ali El Domiaty", title = "A Refined Energy-Based Model for Friction-Stir Welding", abstract = "Friction-stir welding has received a huge interest in the last few years. The many advantages of this promising process have led researchers to present different theoretical and experimental explanation of the process. The way to quantitatively and qualitatively control the different parameters of the friction-stir welding process has not been paved. In this study, a refined energybased model that estimates the energy generated due to friction and plastic deformation is presented. The effect of the plastic deformation at low energy levels is significant and hence a scale factor is introduced to control its effect. The predicted heat energy and the obtained maximum temperature using our model are compared to the theoretical and experimental results available in the literature and a good agreement is obtained. The model is applied to AA6000 and AA7000 series.
", keywords = "Friction-stir welding, Energy, Aluminum Alloys.", volume = "3", number = "5", pages = "605-7", }
