Measurement and simulation of thermal-induced residual stresses within friction stir lapped Al/steel plate
Measurement and simulation of thermal-induced residual stresses within friction stir lapped Al/steel plate
复制标题
测量和模拟摩擦搅拌研磨铝/钢板内的热诱导残余应力
DOI：
10.1016/j.jmatprotec.2022.117760
复制
发表时间：
2022-08-29
影响因子：
6.3
通讯作者：
Fujii, Hidetoshi
中科院分区：
文献类型：
--
作者：
Geng, Peihao;Morimura, Masashi;Fujii, Hidetoshi
焊接残余应力和变形通常会影响装配精度、产品性能和使用寿命，铝/钢混合结构也不例外。采用搅拌摩擦焊技术，在不同转速下对5052铝合金与DP 590钢进行了搭接接头试验。基于JWRIAN软件，结合高效的混合求解方法，建立了一种基于有限元的温度场、残余应力分布和翘曲变形的耦合计算模型。基于模拟结果，较高的旋转速度产生较高的焊接温度和随后的较高的平均冷却速率，导致焊接区附近的纵向拉应力和横向压应力的面积扩展。热膨胀系数不匹配导致两侧近界面残余应力呈镜像分布，尤其是横向残余应力。随着转速的增加，界面附近钢侧的纵向残余应力由压应力状态转变为拉应力状态。随着旋转速度的增加，铝板边缘的最大翘曲变形量增大。用X射线扩散法测量了表面残余应力，用等高线法重建了内部残余应力，并进行了弹性有限元分析。温度历程、残余应力和变形的比较表明，模拟结果与实验结果吻合较好。
Welding residual stress and distortion usually affect the assembly accuracy, product performance, and service life, with no exception for the Al/steel hybrid structure. The lapped joint of 5052 Al alloy and DP590 steel was made by friction stir welding (FSW) at various rotation speeds. A subsequentially coupled computational modeling approach based on the in-house software JWRIAN combining an efficient hybrid solution method was developed to predict the temperature field, the residual stress distribution and the warpage deformation. Based on the simulation, a higher welding temperature with subsequently a higher average cooling rate was created at a high rotation velocity, leading to the area extension of the longitudinal tensile stress and transverse compressive stress near the weld zone. The thermal expansion coefficient mismatch leads to the mirroring distribution of the near interfacial residual stress on both sides, particularly for transverse residual stress. With the increasing rotation speed, the longitudinal residual stress on the steel side near the interface was changed from compressive to the tensile state. The maximum warpage deformation in the Al plate border became larger at a higher rotation speed. The surface residual stress was measured by X-ray diffusion method and the internal residual stress was reconstructed by the contour method with the aid of elastic FE analysis. The comparisons of temperature history, residual stress and deformation indicated satisfactory agreements between simulation and experiment ones.