Experimental and finite element investigations on formability of friction stir welded tailor welded blanks of AA6061 and AA2017

Abstract

Basically, the use of forming limit diagrams has been increased and dertermined as a recognizing technique for obtaining tailor welded blank's formability. In this present investigation, an effort was made to calculate the formability of friction stir welded (FSW) dissimilar alloys by varying the three main process parameters such as tool rotational speed (TRS), weld speed (WS), and tool tilt angle (TTA). All possible combinations of dissimilar sheets were used for experimental and simulation studies to test the limiting dome height. Material characteristics such as densities, young's modulus, as well as all behaviors of blanks were manually allocated for simulation, using true stress vs true strain plots. The simulation process is performed by considering the whole blanck as three zones with heights of limiting dome seem to be nearer with simulation studies and experimental results. With consideration of Forming limit diagram along with assistance of profiles of strain distribution the formability of all dissimilar blanks was evaluated. Blanks that were tailor welded at a TRS of 13,00 rpm, WS of 20 mm/minute, and tool tilt angle considering 10 exhibited higher formability compared to the blanks friction stir welded at various conditions.