Numerical optimisation of laser assisted friction stir welding of structural steel

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Abstract

Significant progress has been made on the implementation of friction stir welding (FSW) in the industry for aluminium alloys. However, steel FSW and other high-temperature alloys is still the subject of considerable research, mainly because of the short life and high cost of the FSW tool. Different auxiliary energies have been considered as a means of optimising the FSW process and reducing the forces on the tool during the plunge and traverse stages, but numerical studies on steel are particularly limited. Building on the state-of-art, laser-assisted steel FSW has been numerically developed and analysed as a viable process amendment. Laser-assisted FSW increased the traverse speed up to 1500 mm min −1, significantly higher than conventional steel FSW. The application of laser assistance with a distance of 20 mm from the rotating tool reduced the reaction force on the tool probe tip up to 55% when compared to standard FSW.

LanguageEnglish
Pages548-558
Number of pages11
JournalScience and Technology of Welding and Joining
Volume24
Issue number6
Early online date23 Jan 2019
DOIs
Publication statusPublished - 5 Jun 2019

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friction stir welding
Friction stir welding
Steel
steels
optimization
Lasers
lasers
heat resistant alloys
Superalloys
aluminum alloys
Aluminum alloys
industries
costs
probes

Keywords

  • laser-assisted friction stir welding
  • finite element modelling
  • coupled Eulerian Lagrangian
  • DH36
  • flash formation
  • temperature distribution

Cite this

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title = "Numerical optimisation of laser assisted friction stir welding of structural steel",
abstract = "Significant progress has been made on the implementation of friction stir welding (FSW) in the industry for aluminium alloys. However, steel FSW and other high-temperature alloys is still the subject of considerable research, mainly because of the short life and high cost of the FSW tool. Different auxiliary energies have been considered as a means of optimising the FSW process and reducing the forces on the tool during the plunge and traverse stages, but numerical studies on steel are particularly limited. Building on the state-of-art, laser-assisted steel FSW has been numerically developed and analysed as a viable process amendment. Laser-assisted FSW increased the traverse speed up to 1500 mm min −1, significantly higher than conventional steel FSW. The application of laser assistance with a distance of 20 mm from the rotating tool reduced the reaction force on the tool probe tip up to 55{\%} when compared to standard FSW.",
keywords = "laser-assisted friction stir welding, finite element modelling, coupled Eulerian Lagrangian, DH36, flash formation, temperature distribution",
author = "Bilal Ahmad and Alexander Galloway and Athanasios Toumpis",
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T1 - Numerical optimisation of laser assisted friction stir welding of structural steel

AU - Ahmad, Bilal

AU - Galloway, Alexander

AU - Toumpis, Athanasios

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N2 - Significant progress has been made on the implementation of friction stir welding (FSW) in the industry for aluminium alloys. However, steel FSW and other high-temperature alloys is still the subject of considerable research, mainly because of the short life and high cost of the FSW tool. Different auxiliary energies have been considered as a means of optimising the FSW process and reducing the forces on the tool during the plunge and traverse stages, but numerical studies on steel are particularly limited. Building on the state-of-art, laser-assisted steel FSW has been numerically developed and analysed as a viable process amendment. Laser-assisted FSW increased the traverse speed up to 1500 mm min −1, significantly higher than conventional steel FSW. The application of laser assistance with a distance of 20 mm from the rotating tool reduced the reaction force on the tool probe tip up to 55% when compared to standard FSW.

AB - Significant progress has been made on the implementation of friction stir welding (FSW) in the industry for aluminium alloys. However, steel FSW and other high-temperature alloys is still the subject of considerable research, mainly because of the short life and high cost of the FSW tool. Different auxiliary energies have been considered as a means of optimising the FSW process and reducing the forces on the tool during the plunge and traverse stages, but numerical studies on steel are particularly limited. Building on the state-of-art, laser-assisted steel FSW has been numerically developed and analysed as a viable process amendment. Laser-assisted FSW increased the traverse speed up to 1500 mm min −1, significantly higher than conventional steel FSW. The application of laser assistance with a distance of 20 mm from the rotating tool reduced the reaction force on the tool probe tip up to 55% when compared to standard FSW.

KW - laser-assisted friction stir welding

KW - finite element modelling

KW - coupled Eulerian Lagrangian

KW - DH36

KW - flash formation

KW - temperature distribution

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