Abstract
In the friction stir welding process, a nonuniform and high generated temperature is undesirable. Unstable temperature and distribution affect thermal and residual stresses along the welding line, thus necessitating mitigation. This paper presents a simple method to prevent significant temperature difference along the welding line and also to help nullifying some defect types associated with this welding, such as end-hole, initial unwelded line, and deformed areas. In the experimental investigation, a heat and force thermocouple and dynamometer were utilized while couple-field thermomechanical models were used to evaluate temperature and its distribution, plastic strain, and material displacement. The suggested method generated uniform temperature distributions. Measurement results are discussed, showing a good correlation with predictions.
Highlights
Friction stir welding (FSW) is becoming more widely used as a manufacturing alternative in aviation, marine, and autoapplications [1]
Heat generated by the FSW process is important in plasticizing the material locally below the tool shoulder
Plunging and dwell time (DT) generate the maximum temperature, which decreases while the tool moves along the welding line [4]
Summary
Friction stir welding (FSW) is becoming more widely used as a manufacturing alternative in aviation, marine, and autoapplications [1]. In FSW, certain associated defects have to be eliminated, and nonuniform temperature distributions along the welding line should be mitigated. Heat generated by the FSW process is important in plasticizing the material locally below the tool shoulder. Frigaard et al [3] developed a thermal model and addressed the brief transition of heat gradients below the shoulder along the thickness direction in four different forms. Plunging and dwell time (DT) generate the maximum temperature, which decreases while the tool moves along the welding line [4]. Temperature varies during the FSW process perpendicularly through the work-piece thickness and longitudinally and transversely along the weld centerline, which results in various evolutions of microstructure and hardness [2]. High temperature in FSW and friction stir processing (FSP) may be undesirable [5, 6]. There is a need for more studies investigating the stability of the resultant temperature
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