Prediction of residual stresses within dissimilar Al/steel friction stir lap welds using an Eulerian-based modeling approach
Prediction of residual stresses within dissimilar Al/steel friction stir lap welds using an Eulerian-based modeling approach
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DOI：
10.1016/j.jmapro.2022.05.001
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发表时间：
2022-07
影响因子：
6.2
通讯作者：
Peihao Geng;Masashi Morimura;Song Wu;Yong Liu;Yunwu Ma;N. Ma;Y. Aoki;H. Fujii;Hong Ma;G. Qin
中科院分区：
文献类型：
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作者：
Peihao Geng;Masashi Morimura;Song Wu;Yong Liu;Yunwu Ma;N. Ma;Y. Aoki;H. Fujii;Hong Ma;G. Qin
采用搅拌摩擦焊（FSW）制备5052铝合金与DP590双相钢搭接异种焊缝。对界面形成和微观结构进行了实验研究，并通过全耦合三维欧拉有限元模型对过程中以残余应力分布为重点的热力学条件进行了数值研究。在旋转销穿透钢的作用下，铝/钢的热-力学相互作用产生锯齿状的结合界面。界面形成脆性金属间层，沿焊接方向分布不连续。仿真结果表明，旋转速度的增加导致焊接温度和冷却速度的提高，从而导致焊接区残余应力水平的增加。近界面残余应力在铝合金中表现为m型，而在钢中表现为w型，这是由热处理条件和热膨胀系数失配的影响造成的。转速的增加降低了钢侧近界面压应力。数值预测的残余应力与采用cosα法进行的x射线扩散测量结果吻合较好，验证了预测的合理性。希望目前的模拟工作将为预测相同或不同FSW内的残余应力场提供一种新的替代建模策略。
Friction stir welding (FSW) was applied to fabricate dissimilar welds between 5052 aluminum alloy and DP590 dual-phase steel with a lap configuration. The interfacial formation and microstructure were investigated experimentally, and in-process thermomechanical conditions with emphasis on resultant residual stress distribution were numerically studied through a fully coupled three-dimensional (3D) Eulerian-based finite element modeling. The Al/steel thermal-mechanical interaction driven by the rotational pin penetrating the steel produced the serrated bonding interface. The brittle intermetallic layer was formed in the interface, showing distribution discontinuity along the welding direction. The simulation results showed that increasing rotation velocity resulted in higher welding temperature and cooling rate, leading to the increment in the residual stress level of the weld zone. Near interfacial residual stresses exhibited an M-shape in the Al alloy while it showed W-shape in the steel, which originated from the thermomechanical processing condition and the effect of mismatch of thermal expansion coefficient. Increasing rotation velocity decreased the near interfacial compressive stress in the steel side. Numerically predicted residual stresses were in acceptable agreement with those measured using the X-ray diffusion measurement with the cosαmethod, validating prediction reasonability. Hopefully, the current simulation work will provide a new alternative modeling strategy for predicting residual stress fields within the same or dissimilar FSW.