A Simulative Method for Studying the Bonding Condition of Friction Stir Extrusion

Abstract:

In the manufacturing industry, the problem related to the management of metal waste is of considerable importance, since it is produced in large quantities during mechanical processing.However, its recovery is not always a simple task, especially with regard to the metal cutting processes. In fact, due to the presence of surface oxide and contaminating oily residues, the recovery process of these components is often very expensive and polluting. This problem can be solved with the FSE process, patented in 1993 by The Welding Institute. The FSE can be counted among the main innovative processing techniques developed in Industry 4.0, as it involves only metal scraps coming from the machining processes as starting material, without providing for their preliminary re-melting in a billet form, and it uses only the heat generated by the friction between the tool and the metal. Since FSE is a quite recent process, the development of simulative models is useful for understanding its basic mechanisms. The objective of this research is to analyze if and how the bonding phenomena occour considering both the thermal and the stress conditions involved and generated by the process parameters.As a result, FEM analysis proved to be a valid tool to correctly forecast if bonding phenomena really take place and how process parameters affect the bonding quality. Moreover, it was possible to confirm that the Piwnik and Plata bonding model is a good criterion for predicting the effects of this technology.

• Periodical: Key Engineering Materials (Volume 926)
• Pages: 2333-2341
• DOI: https://doi.org/10.4028/p-ft5355
• Online since: July 2022
• Authors: Sara Bocchi*, Gianluca Danilo D'Urso, Claudio Giardini, Giancarlo Maccarini
• Keywords: Finite Element Analysis, Friction Stir Extrusion - FSE, Process Sustainability

References

[1] U. Brand, M. Lang, Green Economy, in: P. Pattberg, F. Zelli (Eds.), Encycl. Glob. Environ. Polit. Gov., Cheltenham/Northampton: Edward Elgar, n.d.: p.461–469. https://www.researchgate.net/publication/316890571_Entry_Green_Economy (accessed November 8, 2021).

[2] D. Baffari, G. Buffa, D. Campanella, L. Fratini, Al-SiC Metal Matrix Composite production through Friction Stir Extrusion of aluminum chips, in: Procedia Eng., Elsevier B.V., 2017: p.419–424. https://doi.org/10.1016/j.proeng.2017.10.798.

DOI: 10.1016/j.proeng.2017.10.798

[3] D. Baffari, G. Buffa, D. Campanella, L. Fratini, A.P. Reynolds, Process mechanics in Friction Stir Extrusion of magnesium alloys chips through experiments and numerical simulation, J. Manuf. Process. 29 (2017) 41–49. https://doi.org/10.1016/j.jmapro.2017.07.010.

DOI: 10.1016/j.jmapro.2017.07.010

[4] D. Baffari, A.P. Reynolds, A. Masnata, L. Fratini, G. Ingarao, Friction stir extrusion to recycle aluminum alloys scraps: Energy efficiency characterization, J. Manuf. Process. 43 (2019) 63–69. https://doi.org/10.1016/j.jmapro.2019.03.049.

DOI: 10.1016/j.jmapro.2019.03.049

[5] K. Manchiraju, Direct Solid-State Conversion of Recyclable Metals and Alloys, Southwire Company, Golden, CO (United States), 2012. https://doi.org/10.2172/1039705.

DOI: 10.2172/1039705

[6] R.M. Izatt, ed., Metal sustainability : global challenges, consequences, and prospects, Wiley, (2016).

[7] J. Li, X. Meng, Y. Li, L. Wan, Y. Huang, Friction stir extrusion for fabricating Mg-RE alloys with high strength and ductility, Mater. Lett. 289 (2021) 129414. https://doi.org/10.1016/J.MATLET.2021.129414.

DOI: 10.1016/j.matlet.2021.129414

[8] V.C. Shunmugasamy, E. Khalid, B. Mansoor, Friction stir extrusion of ultra-thin wall biodegradable magnesium alloy tubes — Microstructure and corrosion response, Mater. Today Commun. 26 (2021) 102129. https://doi.org/10.1016/J.MTCOMM.2021.102129.

DOI: 10.1016/j.mtcomm.2021.102129

[9] W.T. Evans, B.T. Gibson, J.T. Reynolds, A.M. Strauss, G.E. Cook, Friction Stir Extrusion: A new process for joining dissimilar materials, Manuf. Lett. 5 (2015) 25–28. https://doi.org/10.1016/J.MFGLET.2015.07.001.

DOI: 10.1016/j.mfglet.2015.07.001

[10] A. Hosseini, E. Azarsa, B. Davoodi, Y. Ardahani, Effect of Process Parameters on the Physical Properties of Wires Produced By Friction Extrusion Method, Int. J. Adv. Eng. Technol. 3 (2012) 2231–1963. https://www.researchgate.net/publication/268013658%0AEffect (accessed March 17, 2021).

[11] H. Zhang, X. Li, W. Tang, X. Deng, A.P. Reynolds, M.A. Sutton, Heat transfer modeling of the friction extrusion process, J. Mater. Process. Technol. 221 (2015) 21–30. https://doi.org/10.1016/j.jmatprotec.2015.01.032.

DOI: 10.1016/j.jmatprotec.2015.01.032

[12] D. Baffari, G. Buffa, L. Fratini, A numerical model for Wire integrity prediction in Friction Stir Extrusion of magnesium alloys, J. Mater. Process. Technol. 247 (2017) 1–10. https://doi.org/10.1016/j.jmatprotec.2017.04.007.

DOI: 10.1016/j.jmatprotec.2017.04.007

[13] R.A. Behnagh, N. Shen, M.A. Ansari, M. Narvan, M. Kazem, B. Givi, H. Ding, Experimental analysis and microstructure modeling of friction stir extrusion of magnesium chips, J. Manuf. Sci. Eng. Trans. ASME. 138 (2016). https://doi.org/10.1115/1.4031281.

DOI: 10.1115/1.4031281

[14] M. Plata, J. Piwnik, Theoretical and experimental analysis of seam weld formation in hot extrusion of aluminum alloys, in: 7th Int. Alum. Extrus. Technol., 2000: p.205–211.

[15] E. Ceretti, L. Fratini, F. Gagliardi, C. Giardini, A new approach to study material bonding in extrusion porthole dies, CIRP Ann. 58 (2009) 259–262. https://doi.org/10.1016/J.CIRP.2009.03.010.

DOI: 10.1016/j.cirp.2009.03.010

[16] E. Ceretti, C. Giardini, Influence of geometrical parameters on material welding in porthole die extrusion: FE analysis, Trans. NAMRI/SME. 38 (2010) 467–474.