Abstract
This contribution offers a study for two numerical approaches of FSW joints for the API 5L-X80 steel. The first one, a pure thermal model, takes into consideration the preponderant frictional force of the tool being in contact with the workpiece. The second model is a computational fluid dynamic approach, which involves determining experimental values for physical constants and observing its influence in viscous dissipation and strain rates of the material. Temperature and thermal history from the FSW processing were recorded and analyzed. The acquired data was provided from two different heat input conditions. In cases of previewing tool or workpiece local temperature, the pure thermal model is a sufficient suitable approach. Conversely, the CFD model frequently requires huge amounts of information, regarding physical constants and experimental variables, becoming a delicate task for its construction. The pure thermal model was able to offer unequivocal temperature results without the need for large experimental data acquisition. This approach was considered to be finer employed when one aims to forecast temperatures in regions proximate to the welding line. The natural complexity associated with FSW processing suggests there are enormous quantities of experimental factors to be considered for the numerical modeling of high-temperature materials. Also, the CFD approach offers distinct results, which might be crucial for understanding the full aspects of experimental variables. A coupled numerical approach with both models is suggested to fully represent the thermophysical aspects of FSW processing.
Highlights
Friction stir welding (FSW) is a manufacturing welding process developed by The Welding Institute in 1991, initially proposed to weld aluminum and other light-weight alloys
This happens due to physical and metallurgical principles, which manage how the heat input is distributed throughout the workpiece
The thermal model showed a practical and straightforward way of finding consistent temperature data regarding different positions of K thermocouples with the experimental values of temperature and with maximum temperatures predicted for the proximities of the welding line
Summary
The advantages of employing FSW, among others, are: joints with superior mechanical properties due to dynamic recrystallization, less harmful manufacturing process and the consolidated union of the welded joint, maintains the chemical composition of the welded joint, offers minimal environmental risks, produces little machining waste and requires little or no surface cleaning (WITEK, 2015). These features inspired the application of FSW in high-temperature alloys such as stainless steels, duplex stainless steels, titanium and nickel alloys, and High Strength Low Alloy (HRLA) steels (SANTOS et al, 2010; ABBASI; NELSON; SORENSEN, 2013; AVILA et al, 2016).
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More From: Revista Mundi Engenharia, Tecnologia e Gestão (ISSN: 2525-4782)
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