Modelling of friction stir welding of DH36 steel

AL-MOUSSAWI, M., SMITH, Alan, YOUNG, Andrew E, CATER, S. and FARAJI, M. (2017). Modelling of friction stir welding of DH36 steel. The International Journal of Advanced Manufacturing Technology, 92 (1-4), 341-360.

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A 3-D computational fluid dynamics (CFD) model was developed to simulate the friction stir welding of 6-mm plates of DH36 steel in an Eulerian steady-state framework. The viscosity of steel plate was represented as a non- Newtonian fluid using a flow stress function. The PCBN-WRe hybrid tool was modelled in a fully sticking condition with the cooling system effectively represented as a negative heat flux. The model predicted the temperature distribution in the stirred zone (SZ) for six welding speeds including low, intermediate and high welding speeds. The results showed higher asymmetry in temperature for high welding speeds. Thermocouple data for the high welding speed sample showed good agreement with the CFD model result. The CFD model results were also validated and compared against previous work carried out on the same steel grade. The CFD model also predicted defects such as wormholes and voids which occurred mainly on the advancing side and are originated due to the local pressure distribution between the advancing and retreating sides. These defects were found to be mainly coming from the lack in material flow which resulted from a stagnant zone formation especially at high tra- verse speeds. Shear stress on the tool surface was found to in- crease with increasing tool traverse speed. To produce a “sound” weld, the model showed that the welding speed should remain between 100 and 350 mm/min. Moreover, to prevent local melt- ing, the maximum tool’s rotational speed should not exceed 550 RPM.

Item Type: Article
Uncontrolled Keywords: Original Article, Friction stir welding (FSW), Computational fluid dynamics (CFD), DH36, Weld defects
Research Institute, Centre or Group - Does NOT include content added after October 2018: Materials and Engineering Research Institute > Structural Materials and Integrity Research Centre > Centre for Corrosion Technology
Materials and Engineering Research Institute > Structural Materials and Integrity Research Centre > Centre for Infrastructure Management
Identification Number:
Page Range: 341-360
Depositing User: Jill Hazard
Date Deposited: 13 Mar 2017 14:39
Last Modified: 18 Mar 2021 01:03

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