Parametric finite-element studies on the effect of tool shape in friction stir welding

Research output: Contribution to journalArticle

7 Citations (Scopus)

Abstract

The success of the Friction Stir Welding (FSW) process, and the weld quality produced, depends significantly on the design of the welding tool. In this paper the effect of variation in various tool geometry parameters on FSW process outcomes, during the plunge stage, were investigated. Specifically the tool shoulder surface angle and the ratio of the shoulder radius to pin radius on tool reaction force, tool torque, heat generation, temperature distribution and size of the weld zone were investigated. The studies were carried out numerically using the finite element method. The welding process used AA2024 aluminium alloy plates with a thickness of 3 mm. It was found that, in plunge stage, the larger the pin radius the higher force and torque the tool experiences and the greater heat generated. It is also found that the shoulder angle has very little effect on energy dissipation as well as little effect on temperature distribution.
LanguageEnglish
Pages1161-1173
Number of pages13
JournalProceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
Volume224
Issue number8
DOIs
Publication statusPublished - 1 Aug 2010

Fingerprint

Friction stir welding
Welding
Welds
Temperature distribution
Torque
Heat generation
Aluminum alloys
Energy dissipation
Finite element method
Geometry

Keywords

  • finite element method
  • energy dissipation
  • temperature distribution
  • friction stir welding
  • tool shape

Cite this

@article{70e719362d634d02a20e376dee774602,
title = "Parametric finite-element studies on the effect of tool shape in friction stir welding",
abstract = "The success of the Friction Stir Welding (FSW) process, and the weld quality produced, depends significantly on the design of the welding tool. In this paper the effect of variation in various tool geometry parameters on FSW process outcomes, during the plunge stage, were investigated. Specifically the tool shoulder surface angle and the ratio of the shoulder radius to pin radius on tool reaction force, tool torque, heat generation, temperature distribution and size of the weld zone were investigated. The studies were carried out numerically using the finite element method. The welding process used AA2024 aluminium alloy plates with a thickness of 3 mm. It was found that, in plunge stage, the larger the pin radius the higher force and torque the tool experiences and the greater heat generated. It is also found that the shoulder angle has very little effect on energy dissipation as well as little effect on temperature distribution.",
keywords = "finite element method, energy dissipation, temperature distribution, friction stir welding, tool shape",
author = "H. Li and D. Mackenzie and R. Hamilton",
year = "2010",
month = "8",
day = "1",
doi = "10.1243/09544054JEM1810",
language = "English",
volume = "224",
pages = "1161--1173",
journal = "Proceedings for Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture",
issn = "0954-4054",
number = "8",

}

TY - JOUR

T1 - Parametric finite-element studies on the effect of tool shape in friction stir welding

AU - Li, H.

AU - Mackenzie, D.

AU - Hamilton, R.

PY - 2010/8/1

Y1 - 2010/8/1

N2 - The success of the Friction Stir Welding (FSW) process, and the weld quality produced, depends significantly on the design of the welding tool. In this paper the effect of variation in various tool geometry parameters on FSW process outcomes, during the plunge stage, were investigated. Specifically the tool shoulder surface angle and the ratio of the shoulder radius to pin radius on tool reaction force, tool torque, heat generation, temperature distribution and size of the weld zone were investigated. The studies were carried out numerically using the finite element method. The welding process used AA2024 aluminium alloy plates with a thickness of 3 mm. It was found that, in plunge stage, the larger the pin radius the higher force and torque the tool experiences and the greater heat generated. It is also found that the shoulder angle has very little effect on energy dissipation as well as little effect on temperature distribution.

AB - The success of the Friction Stir Welding (FSW) process, and the weld quality produced, depends significantly on the design of the welding tool. In this paper the effect of variation in various tool geometry parameters on FSW process outcomes, during the plunge stage, were investigated. Specifically the tool shoulder surface angle and the ratio of the shoulder radius to pin radius on tool reaction force, tool torque, heat generation, temperature distribution and size of the weld zone were investigated. The studies were carried out numerically using the finite element method. The welding process used AA2024 aluminium alloy plates with a thickness of 3 mm. It was found that, in plunge stage, the larger the pin radius the higher force and torque the tool experiences and the greater heat generated. It is also found that the shoulder angle has very little effect on energy dissipation as well as little effect on temperature distribution.

KW - finite element method

KW - energy dissipation

KW - temperature distribution

KW - friction stir welding

KW - tool shape

U2 - 10.1243/09544054JEM1810

DO - 10.1243/09544054JEM1810

M3 - Article

VL - 224

SP - 1161

EP - 1173

JO - Proceedings for Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

T2 - Proceedings for Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

JF - Proceedings for Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

SN - 0954-4054

IS - 8

ER -