Finite element modeling of friction stir welding - thermal and thermomechanical analysis
Finite element modeling of friction stir welding - thermal and thermomechanical analysis
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DOI：
10.1016/s0890-6955(03)00158-5
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发表时间：
2003-10-01
影响因子：
14
通讯作者：
Kovacevic, R
中科院分区：
文献类型：
--
作者：
Chen, CM;Kovacevic, R
搅拌摩擦焊(FSW)是一种相对较新的焊接工艺，与传统的熔合工艺相比，它具有以下显著优点：传统的非熔化焊接合金的连接，由于金属的纯固态连接，减少了变形，并改善了可焊接合金接头的力学性能。本文采用基于有限元分析的三维模型，研究了6061-T6铝合金对接焊接过程中的热历史和热机械过程。该模型综合了刀具的机械反作用和焊接材料的热机械过程。模型中包含的热源涉及材料与探头和肩部之间的摩擦。为了给理解搅拌摩擦焊热机械过程的动力学提供一个定量的框架，对搅拌摩擦焊焊接过程的热历史以及纵向、横向和穿透应力的演化进行了数值模拟。利用X射线衍射仪对焊接板的残余应力进行了测量，并用测量结果验证了该模型的有效性。给出了计算的焊缝残余应力与刀具移动速度等工艺参数之间的关系。可以预期，该模型可以扩展到优化搅拌摩擦焊工艺，以最小化焊接残余应力。(C)2003爱思唯尔有限公司。保留所有权利。
Friction stir welding (FSW) is a relatively new welding process that may have significant advantages compared to the fusion processes as follow: joining of conventionally non-fusion weldable alloys, reduced distortion and improved mechanical properties of weldable alloys joints due to the pure solid-state joining of metals. In this paper, a three-dimensional model based on finite element analysis is used to study the thermal history and thermomechanical process in the butt-welding of aluminum alloy 6061-T6. The model incorporates the mechanical reaction of the tool and thermomechanical process of the welded material. The heat source incorporated in the model involves the friction between the material and the probe and the shoulder. In order to provide a quantitative framework for understanding the dynamics of the FSW thermomechanical process, the thermal history and the evolution of longitudinal, lateral, and through-thickness stress in the friction stirred weld are simulated numerically. The X-ray diffraction (XRD) technique is used to measure the residual stress of the welded plate, and the measured results are used to validate the efficiency of the proposed model. The relationship between the calculated residual stresses of the weld and the process parameters such as tool traverse speed is presented. It is anticipated that the model can be extended to optimize the FSW process in order to minimize the residual stress of the weld. (C) 2003 Elsevier Ltd. All rights reserved.