The Advances in Joining Technology

107 Pages·2019·4.499 MB·English

by  Mokhtar Awang

Lecture Notes in Mechanical Engineering
Editor
Mokhtar Awang
The Advances
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Mokhtar Awang
Editor
The Advances in Joining
Technology
123
Editor
Mokhtar Awang
Department ofMechanical Engineering
Universiti TeknologiPETRONAS
Seri Iskandar
Malaysia
ISSN 2195-4356 ISSN 2195-4364 (electronic)
Lecture Notesin MechanicalEngineering
ISBN978-981-10-9040-0 ISBN978-981-10-9041-7 (eBook)
https://doi.org/10.1007/978-981-10-9041-7
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Contents
Thermal Modelling of Friction Stir Welding (FSW) Using Calculated
Young’s Modulus Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bahman Meyghani, M. Awang, S. Emamian
and Mohd Khalid B. Mohd Nor
The Effect of Pin Profiles and Process Parameters on Temperature
and Tensile Strength in Friction Stir Welding of AL6061 Alloy. . . . . . . 15
S. Emamian, M. Awang, F. Yusof, Patthi Hussain, Bahman Meyghani
and Adeel Zafar
The Effect of Argon Shielding Gas Flow Rate on Welded 22MnB5
Boron Steel Using Low Power Fiber Laser . . . . . . . . . . . . . . . . . . . . . . 39
Khairul Ihsan Yaakob, Mahadzir Ishak and Siti Rabiatull Aisha Idris
Effect of Bevel Angle and Welding Current on T-Joint Using Gas
Metal Arc Welding (GMAW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Z. A. Zakaria, M. A. H. Mohd Jasri, Amirrudin Yaacob, K. N. M. Hasan
and A. R. Othman
Laser Brazing Between Sapphire and Inconel 600 . . . . . . . . . . . . . . . . . 59
Shamini Janasekaran, Farazila Yusof and Mohd Hamdi Abdul Shukor
A Review on Underwater Friction Stir Welding (UFSW). . . . . . . . . . . . 71
Dhanis Paramaguru, Srinivasa Rao Pedapati and M. Awang
Three Response Optimization of Spot-Welded Joint Using Taguchi
Design and Response Surface Methodology Techniques. . . . . . . . . . . . . 85
F. A. Ghazali, Z. Salleh, Yupiter H. P. Manurung, Y. M. Taib,
Koay Mei Hyie, M. A. Ahamat and S. H. Ahmad Hamidi
A Review on Mechanical Properties of SnAgCu/Cu Joint Using
Laser Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Nabila Tamar Jaya, Siti Rabiatull Aisha Idris and Mahadzir Ishak
v
Thermal Modelling of Friction Stir
Welding (FSW) Using Calculated
Young’s Modulus Values
BahmanMeyghani,M.Awang,S.EmamianandMohdKhalidB.MohdNor
Abstract The temperature fluctuations present in Friction Stir Welding (FSW),
require,detailedthermalanalysisoftheprocess.Toachievehighlyaccurateresultsfor
theanalysis,reliablematerialdatashouldbeobtained.Nevertheless,thematerialdata
thatarepresentedintheliteratureareusuallylimitedtolowerstrainrateregimesand
lowertemperatures.Thus,calculatingthetemperaturedependentmaterialproperties
helpsimprovetheaccuracyofthestimulatedmodel.Toachieveareliablematerial
datainthehigherrangeoftemperatures,thispaperpresentsamathematicalformu-
lationforcalculatingtemperaturedependentYoung’smodulusvalues.MATLAB®
andABAQUS®softwareareemployedforsolvingthegoverningequationsandmod-
ellingtheprocess,respectively.Tocomparetheresultsandfindtheerrorpercentage,
thecalculatedandthedocumented(constant)valuesofYoung’smodulusareapplied
intotwodistinctfiniteelementmodels.Finally,thedevelopedmodelisvalidatedby
comparingtheresultsobtainedfromexperimentswithpublishedresults.
· ·
Keywords Temperaturefluctuations Frictionstirwelding(FSW) Mathematical
·
formulation Young’smodulus
1 Introduction
FSWcombinesbothmechanicalandthermalphenomena.Basically,thetemperature
evaluation surrounding and inside the stirring zone (SZ) is dominated by severe
plasticdeformationandfrictionalforce[1].Toclarifythepoint,plasticdeformation
producesmechanicalenergyandsomepartsofthismechanicalenergyistransformed
B
B.Meyghani·M.Awang( )·S.Emamian
DepartmentofMechanicalEngineering,FacultyofEngineering,UniversitiTeknologi
PETRONAS,BandarSeriIskandar32610,PerakDarulRidzuan,Malaysia
e-mail:[email protected]
M.K.B.MohdNor
FrictionandForgeProcessesGroup,JoiningTechnologiesGroup,TWILtd,Cambridge,UK
©SpringerNatureSingaporePteLtd.2019 1
M. Awang (ed.), The Advances in Joining Technology, Lecture Notes in Mechanical
Engineering,https://doi.org/10.1007/978-981-10-9041-7_1
2 B.Meyghanietal.
intoheat[2].Thisissuecausespermanentmicrostructuralchangesandalsochanges
thephaseofthematerial.
Many studies have been done to investigate the temperature behaviour during
the FSW process by using experimental procedures [3–5], however, for detailed
understandingandanalysethethermalbehaviour,experimentalmethodsareusually
costly and time consuming. Finite Element Methods (FEMs) is recommended as
apowerfultoolandaneffectivenumericaltechniqueforsolvingpartialdifferential
equations(PDEs)inengineering,thereforeFEMsareacheaperandquickerapproach
forinvestigatingtheprocess.AschematicviewoftheFSWisdescribedinFig.1.
Asdiscussedearlier,themostsignificantfactorsforthegenerationoftheheatare
frictionalforceandplasticdeformation[6,7].Therefore,toobtainmorepreciseanal-
ysisoftheprocess,itiscrucialtopreciselydefinethematerialplasticitybehaviour.
Oneofthemostsignificantinputparameterswhichisinfluencingtheaccuracyofthe
simulatedmodelisYoung’smodulus.However,Young’smodulusthatwereusedin
theliterature,usuallyobtainedfromtheexperimentaldataorgainedfromthelitera-
ture[8–10].Additionally,thevaluesareoftenrestrictedtolowerstrainrateregimes
andlowertemperatures.While,temperatureinFSWcanreachupto60–80%ofthe
basematerialmeltingtemperature[11].
Inrecentyears,theFSWprocessmodellinghasbeenresearchedinbothacademic
andindustrialorganisations.ALagrangian–Eulerian(adaptivearbitraryformulation)
was established to compute the evolution of the temperature and the flow of the
materialthroughouttheFSWprocess[12].Inthemodel,Young’smoduluswaskept
constantat73GPaandthePoisson’sratiowasassumedtobe0.3.Inthisresearch,
3D Forge3® FE software with automatic remeshing was utilised to implement the
formulation. The results indicated that the accuracy of the model in the tempera-
Fig.1 Theprocessschematicviewandrotationdirection
ThermalModellingofFrictionStirWelding(FSW)Using… 3
turepredictionishighlydependenttotheuseofconstantortemperaturedependent
materialproperties.
ThearbitraryLagrangian–Eulerian(ALE)methodwasusedtodevelopa3DFE
model in ABAQUS®/Explicit by utilising Coulomb law of friction and Johnson—
Cook material law [8]. The study found that the generation of the heat during the
processcanbecategorisedintotwovariousparts,theheatgeneratedbythedeforma-
tionofthematerialnearthepinandtheshoulder,andthefrictionalforce.Inaddition,
the numerical results of the paper indicated that the heat generated by the friction
hasmoreimpactincomparisontotheheatproducedbytheplasticdeformation.The
studyalsodemonstratedthatsomeportionsoftheheatistheresultofthesliprate.
Meanwhile, it was claimed that, the heat from the plastic deformation is linked to
thematerialvelocity.
Toestimatetheresidualstressesandthepeaktemperature,astationaryshoulder
wasusedinastudy[9]inwhichaconstantYoung’smodulusandPoisson’sratioof
71.7and0.33GPahavebeenemployed,respectively.Itwasobservedthat,through
thethicknessofthematerial,theprocessproducedamoreuniformandanarrower
nugget zone and the heat affected zone. Furthermore, ‘M’ shaped residual stress
distributionswereobtained.
Meanwhile,afiniteelement(FE)analysiswasemployedforsimulatingthestress,
the effective strain distribution and the temperature on the workpiece surface for
differentpinprofiles[10].Themodelusedaconstantelasticmodulusof68.9GPa
and a constant Poison’s ratio of 0.3. The study examined the fracture surfaces at
both microscopic and macroscopic levels to investigate the welded joints fracture
behaviour.Itwasfoundthatthecrackinitiatedfromtheperipheryofthejoint,and
thefailureofthejointsmainlyoccurredduetothethinningoftheuppersheet.
Astudypresented[13]asolidapproachbyusingaconstantPoisson’sratioof0.33
andYoung’smodulusof70.4GPaforthermomechanicalsimulationofFSW.Two
numerical models (three dimensional models) were compared representing FSW
procedureswithatrigonalpin.Oneofthemodelswasbasedonasolidformulation,
whiletheotheronewasbasedonafluidformulation.AuthorsusedNorton–Hoffcon-
stitutivemodelwithhighsensitivitytothetemperature,andtheArbitraryLagrangian
Eulerian(ALE)method.Itwasconcludedthat,thetwomentionedformulationslead
tothesameresults.
Inamodel[14]aconstantpoisonratioof0.33andYoung’smodulusof68.9GPa
were applied to the model. The paper proposed a 3D coupled thermo-mechanical
model, which was based on the Lagrangian implicit approach to examine the dis-
tribution of the strain and also to observe the thermal history of Aluminium alloy
2024buttweldingusingtheDEFORM-3D® software.Itwasobservedthatthereis
anasymmetricnatureintheweldingnuggetzone.Furthermore,itwasfoundthatthe
topsurfaceoftheworkpiecehasthemaximumtemperature.
Inthemeantime,somestudiesadaptedtemperaturedependentmaterialproperties
[15–18].Thematerialcharacteristicswereintroduced[15]tomodeltheprocessusing
theconstantPoisson’sratioof0.33,andthetemperaturedependentYoung’smodulus
rangingfrom68.9GPain25°C–31.72GPain426.7°C.Moreover,inthemodelthe
relationship between the tool moving speed, the heat distribution and the residual
4 B.Meyghanietal.
stresswereinvestigated.Theanalysisoftheprocesswasclassifiedintotwostages;the
firststageinvolvedthestudyingoftheworkpiecethermalbehaviourwheretheheat
wasgeneratedbecauseofthefrictionbetweentheinterfacesofthetool/workpiece.
Meanwhile, in the next stage, the workpiece thermal behaviour (investigated from
thefirststage)wastakenintoaccountasaninletheatwhichrepresentstheelasto-
plasticbehaviour.Inthelatterstepofthesimulation,thetoolwasremovedafterthe
welding and the distributions of the residual stress was measured after completely
coolingoftheworkpiece(whentheclampwasdisassembled).Theresultsobtained
showedthat,thepatternofthedistributionoftheheatvariedalongthethicknessis
largelyasymmetrical.Furthermore,itwasobservedthat,astheweldingtransverse
and rotational movements increased, the welding longitudinal residual stress also
increased.Itshouldbenotedthat,onlytheheatimpactwasconsideredforpredict-
ing the residual stress. Therefore, it was deemed as the main factor of the minor
differencesbetweentheactualexperimentandthesimulation.
Astudyhaddevelopeda3-dimensionallocalisedFEMforpredictingtheprobable
resultsforthedefectsgenerationwithintheFSW[18].TheLagrangianformulation
hadbeenusedtomodelthetool,whiletheEulerianformulationwasusedtomodel
theworkpiece.Besidesthat,theCoulomblawoffrictionwasusedfordefiningthe
interactions between the interfaces of the tool/workpiece. Moreover, the material
inflow and outflow velocities were used to define the welding speeds. The study
hadconsideredthetemperaturedependentYoung’smodulus,rangingfrom66.94to
20.2GPawhenthetemperaturevariationis25–482°C.Theresultsinvestigatedthat
byconsideringtheadiabaticheatingeffect,themaximumestimatedtemperatureof
583°Cwasobtained,whichwassimilartothematerialsolidustemperature(based
onJohnson–Cookmaterialmodel).
The temperature dependent Young’s modulus was adopted to investigate the
mechanicalbehaviourofthematerialduringhightemperatureforweldingof6xxx
aluminiumalloyseries[17].Basedontheresult,thetemperaturehadcontinuously
changedduringthewelding;firstly,thetemperaturehadrisen,thenitdecreased(dur-
ingthecoolingdownperiod).Itshouldbenotedthat,thedwell-timeatthemaximum
temperaturewasnotconsideredinthemodel.Thestudyalsoexamined,thetensile
testsduringtheheatingandthecoolingrateofthespecimen.Moreover,acomparison
betweenthecalculatedandthemeasuredstress-straincurveswasdonetovalidatethe
accuracyofthethermomechanicaldatabase.Thissuggeststhat,thisapproachcould
beusefulinpredictingthealloystensilebehaviourathightemperatures.Lastly,the
numericalandtheexperimentalresultsforthetemperatureandtheresidualstresses
werecomparedandagoodagreementwasfound.
Meanwhile,Azizetal.[16]employedYoung’smodulusasatemperaturefunc-
tion in a study for developing thermomechanical modelling FSW of aluminium
(AA2219)–copperalloy.Furthermore,theyinvestigatedtheheatgenerationthrough-
outtheprocess.ThemodelwasdevelopedbyusingANSYS®APDLandtheresults
wereverifiedthroughconductingacomparisonofthetemperatureprofilebetween
the experimental observations and the results obtained from the simulated model.
Threedifferentconditions(variousweldingspeeds)inexperimentalandnumerical
modelswereconsideredandtheverifiedFEmodelwasusedtoanalysetheinfluence