Effects of FSW Tool Plunge Depth on Properties of an Al-Mg-Si Alloy T-Joint: Thermomechanical Modeling and Experimental Evaluation - Publication - Bridge of Knowledge

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Effects of FSW Tool Plunge Depth on Properties of an Al-Mg-Si Alloy T-Joint: Thermomechanical Modeling and Experimental Evaluation

Abstract

One of the main challenging issues in friction stir welding (FSW) of stiffened structures is maximizing skin and flange mixing. Among the various parameters in FSW that can affect the quality of mixing between skin and flange is tool plunge depth (TPD). In this research, the effects of TPD during FSW of an Al-Mg-Si alloy T-joint are investigated. The computational fluid dynamics (CFD) method can help understand TPD effects on FSW of the T-joint structure. For this reason, the CFD method is employed in the simulation of heat generation, heat distribution, material flow, and defect formation during welding processes at various TPD. CFD is a powerful method that can simulate phenomena during the mixing of flange and skin that are hard to assess experimentally. For the evaluation of FSW joints, macrostructure visualization is carried out. Simulation results showed that at higher TPD, more frictional heat is generated and causes the formation of a bigger stir zone. The temperature distribution is antisymmetric to the welding line, and the concentration of heat on the advancing side (AS) is more than the retreating side (RS). Simulation results from viscosity changes and material velocity study on the stir zone indicated that the possibility of the formation of a tunnel defect on the skin–flange interface at the RS is very high. Material flow and defect formation are very sensitive to TPD. Low TPD creates internal defects with incomplete mixing of skin and flange, and high TPD forms surface flash. Higher TPD increases frictional heat and axial force that diminish the mixing of skin and flange in this joint. The optimum TPD was selected due to the best materials flow and final mechanical properties of joints.

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Authors (5)

  • Photo of  Shabbir Memon

    Shabbir Memon

    • Department of Mechanical Engineering, Wichita State University, Wichita, KS 67260-133, USA
  • Photo of  Aintzane Conde Fernandez

    Aintzane Conde Fernandez

    • Department of Mechanics, Design and Industrial Management, University of Deusto, Avda Universidades 24, 48007 Bilbao, Spain
  • Photo of  Hamed Aghajani Derazkola

    Hamed Aghajani Derazkola

    • Department of Mechanics, Design and Industrial Management, University of Deusto, Avda Universidades 24, 48007 Bilbao, Spain
  • Photo of  Hesamoddin Aghajani Derazkola

    Hesamoddin Aghajani Derazkola

    • Department of Mechanical Engineering, University of Mazandaran, Babolsar 47415, Iran

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DOI:
Digital Object Identifier (open in new tab) 10.3390/ma14164754
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Details

Category:
Articles
Type:
artykuły w czasopismach
Published in:
Materials no. 14,
ISSN: 1996-1944
Language:
English
Publication year:
2021
Bibliographic description:
Memon S., Fydrych D., Fernandez A. C., Derazkola H. A., Derazkola H. A.: Effects of FSW Tool Plunge Depth on Properties of an Al-Mg-Si Alloy T-Joint: Thermomechanical Modeling and Experimental Evaluation// Materials -Vol. 14,iss. 16 (2021), s.4754-
DOI:
Digital Object Identifier (open in new tab) 10.3390/ma14164754
Verified by:
Gdańsk University of Technology

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