Numerical Investigation Into the Influence of Alloy Type and Thermo-Mechanics on Void Formation in Friction Stir Welding of Aluminum Alloys
Numerical Investigation Into the Influence of Alloy Type and Thermo-Mechanics on Void Formation in Friction Stir Welding of Aluminum Alloys
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合金类型和热力学对铝合金搅拌摩擦焊空洞形成影响的数值研究
DOI：
10.1115/1.4062270
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发表时间：
2023
期刊：
影响因子：
--
通讯作者：
Rudraraju, Shiva
中科院分区：
文献类型：
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作者：
Ansari, Mohammad Ali;Agiwal, Hemant;Franke, Daniel;Zinn, Michael;Pfefferkorn, Frank E.;Rudraraju, Shiva
本研究采用了高保真的数值框架，以确定塑性材料的流动模式和温度分布，导致在搅拌摩擦焊（FSW）过程中形成的空隙，并与底层合金材料的性能和工艺条件的空隙形态。三种铝合金，即，6061-T6、7075-T6和5053-H18在不同横移速度下进行了研究。铝合金的选择使研究范围广泛的热性能和机械性能成为可能。数值模拟进行了验证，使用实验观察这三种合金中的空隙形态。温度，塑性应变速率，和材料流动模式被认为是。本研究的主要结果如下：（1）预测的搅拌区和空洞形态与实验观察结果吻合良好，（2）稳态工艺条件下的温度和塑性应变速率图显示出对合金类型和横向速度的强烈依赖性，（3）材料速度等值线提供了对于导致空隙以及不导致空隙的FSW工艺条件的搅拌区中的材料流动的良好洞察。在这项研究中提出的数值模型和随后的参数研究提供了一个框架，了解在不同的工艺条件下，在铝合金和潜在的其他合金的材料流。此外，效用的数值模型进行定量预测和调查不同的工艺参数，以减少空隙的形成。
This study employs a high-fidelity numerical framework to determine the plastic material flow patterns and temperature distributions that lead to void formation during friction stir welding (FSW), and to relate the void morphologies to the underlying alloy material properties and process conditions. Three aluminum alloys, viz., 6061-T6, 7075-T6, and 5053-H18, were investigated under varying traverse speeds. The choice of aluminum alloys enables the investigation of a wide range of thermal and mechanical properties. The numerical simulations were validated using experimental observations of void morphologies in these three alloys. Temperatures, plastic strain rates, and material flow patterns are considered. The key results from this study are as follows: (1) the predicted stir zone and void morphology are in good agreement with the experimental observations, (2) the temperature and plastic strain rate maps in the steady-state process conditions show a strong dependency on the alloy type and traverse speeds, (3) the material velocity contours provide a good insight into the material flow in the stir zone for the FSW process conditions that result in voids as well as those that do not result in voids. The numerical model and the ensuing parametric studies presented in this study provide a framework for understanding material flow under different process conditions in aluminum alloys and potentially in other alloys. Furthermore, the utility of the numerical model for making quantitative predictions and investigating different process parameters to reduce void formation is demonstrated.