Numerical Investigation on Dissimilar Friction Stir Welding of Aluminum and Magnesium Sheets

Abstract:

Friction Stir Welding (FSW) is a solid-state welding process used to weld difficult to be welded or unweldable materials as aluminum alloys. In the last years other materials have been successfully tested as magnesium, titanium and nickel based alloys. Mixed joints can be obtained by FSW but issues arise in the correct choice of the process parameters. In the paper a numerical model is presented for the prediction of the main field variables distribution and the occurring material flow in FSW of dissimilar AA6061 and AZ31 butt joints. Important insights are obtained on the effect of the mutual position of the two materials with respect to the advancing and retreating side of the joint has been highlighted.

• Periodical: Key Engineering Materials (Volumes 622-623)
• Pages: 532-539
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.622-623.532
• Online since: September 2014
• Authors: Gianluca Buffa*
• Keywords: Aluminium Alloy, FEM, Magnesium Alloy, Mixed Joints

References

[1] R.S. Mishra and Z.Y. Ma, Friction stir welding and processing, Mat Sci Eng R, 50 (2005) 1-78.

[2] K. Colligan, Material flow behavior during friction stir welding of aluminum, Welding Journal (Miami, Fla), 78 (1999) 229-s.

[3] C. Bruni, G. Buffa, L. D'Apolito, A. Forcellese and L. Fratini, Tool geometry in friction stir welding of magnesium alloy sheets, 410-411 (2009) 555-562.

DOI: 10.4028/www.scientific.net/kem.410-411.555

[4] N. Afrin, D.L. Chen, X. Cao and M. Jahazi, Microstructure and tensile properties of friction stir welded AZ31B magnesium alloy, Mater. Sci. Eng., A, 472 (2008) 179-186.

DOI: 10.1016/j.msea.2007.03.018

[5] Y.J. Kwon, I. Shigematsu and N. Saito, Dissimilar friction stir welding between magnesium and aluminum alloys, Mater. Lett., 62 (2008) 3827-3829.

DOI: 10.1016/j.matlet.2008.04.080

[6] Y.S. Sato, S.H.C. Park, M. Michiuchi and H. Kokawa, Constitutional liquation during dissimilar friction stir welding of Al and Mg alloys, Scripta Mater., 50 (2004) 1233-1236.

DOI: 10.1016/j.scriptamat.2004.02.002

[7] X. Deng and S. Xu, Two-dimensional finite element simulation of material flow in the friction stir welding process, Journal of Manufacturing Processes, 6 (2004) 125-133.

DOI: 10.1016/s1526-6125(04)70066-3

[8] P. Ulysse, Three-dimensional modeling of the friction stir-welding process, International Journal of Machine Tools and Manufacture, 42 (2002) 1549-1557.

DOI: 10.1016/s0890-6955(02)00114-1

[9] C.M. Chen and R. Kovacevic, Finite element modeling of friction stir welding - Thermal and thermomechanical analysis, International Journal of Machine Tools and Manufacture, 43 (2003) 1319-1326.

DOI: 10.1016/s0890-6955(03)00158-5

[10] P.A.S. Colegrove, H.R.; Hyoe, T., Development of the TrivexTM Friction Stir Welding tool for making lap welds, 5th International Symposium on Friction Stir Welding, (2004).

DOI: 10.1002/9781118062302.ch30

[11] G. Buffa, J. Hua, R. Shivpuri and L. Fratini, A continuum based FEM model for friction stir welding - model development, Mat Sci Eng a-Struct, 419 (2006) 389-396.

DOI: 10.1016/j.msea.2005.09.040

[12] G. Buffa, A. Ducato and L. Fratini, Dissimilar material lap joints by friction stir welding of steel and titanium sheets: Process modeling, 1532 (2013) 491-498.

DOI: 10.1063/1.4806866

[13] C. Bruni, G. Buffa, L. Fratini and M. Simoncini, Friction stir welding of magnesium alloys under different process parameters, 638-642 (2010) 3954-3959.

DOI: 10.4028/www.scientific.net/msf.638-642.3954

[14] JMatPro Demo version, Surrey Technology Centre 40 Occam Road GU2 7YG United Kingdom.