Numerical simulation of material flow in AA6082 during friction stir spot welding

Authors

  • Zeng Gao School of Materials Science and Engineering, Henan Polytechnic University, Henan, Jiaozuo, 454003, China
  • Peng Wang School of Materials Science and Engineering, Henan Polytechnic University, Henan, Jiaozuo, 454003, China
  • Dongfeng Cheng School of Materials Science and Engineering, Henan Polytechnic University, Henan, Jiaozuo, 454003, China
  • Jitai Niu School of Materials Science and Engineering, Henan Polytechnic University, Henan, Jiaozuo, 454003, China; Henan Jingtai Aerospace High-Novel Materials Technology Co., Ltd, Henan, Jiaozuo, 454003, China
  • Christof Sommitsch Institute for Materials Science and Welding, Graz University of Technology – Graz, 8010, Austria

Keywords:

friction stir spot welding, AA 6082, material flow, numerical simulation, effective strain rate

Abstract

Friction stir spot welding (FSSW) is a new solid state joining technology based on the linear friction stir welding which can be used to replace the conventional resistance spot welding as well as riveting. However, some key problems such as heat transfer and thermoplastic material flow have not yet been studied sufficiently and block the application of this advanced technology. This paper presents the coupled thermo-mechanical viscoplastic finite element formulation based on the character of FSSW. The model was calibrated by comparing temperature history between simulation results and experimental data and subsequently used to investigate the effective strain rate and material flow in joint. The temperature study showed that the simulation and experiment results coincided well with each other thus proofing the correctness of the model. The simulation results showed that the effective strain rate distribution were not uniform. The material close to the pin’s cylindrical surface had a higher effective strain rate than that of the other material. The materials in weld centre mainly experienced a compression process and the other material under the tool experienced both compression and shear process.

Author Biographies

Zeng Gao, School of Materials Science and Engineering, Henan Polytechnic University, Henan, Jiaozuo, 454003, China

School of Materials Science and Engineering, Associate Professor, Dr.

Peng Wang, School of Materials Science and Engineering, Henan Polytechnic University, Henan, Jiaozuo, 454003, China

School of Materials Science and Engineering

Dongfeng Cheng, School of Materials Science and Engineering, Henan Polytechnic University, Henan, Jiaozuo, 454003, China

School of Materials Science and Engineering

Jitai Niu, School of Materials Science and Engineering, Henan Polytechnic University, Henan, Jiaozuo, 454003, China; Henan Jingtai Aerospace High-Novel Materials Technology Co., Ltd, Henan, Jiaozuo, 454003, China

School of Materials Science and Engineering

Christof Sommitsch, Institute for Materials Science and Welding, Graz University of Technology – Graz, 8010, Austria

Institute for Materials Science and Welding

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Published

2015-10-13

Issue

Engineering Review, Vol. 35, No. 3

Section

Articles

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