Numerical Simulation of Residual Stress in Friction Stir Lap Welding of Al-Mg Dissimilar Alloy

WU Xiaohu; CAO Lijie; MIAO Chenhuai; WANG Yi

doi:10.11973/jxgccl202207017

Materials and Mechanical Engineering > 2022 > 46(7): 95-102. > DOI: 10.11973/jxgccl202207017

WU Xiaohu, CAO Lijie, MIAO Chenhuai, WANG Yi. Numerical Simulation of Residual Stress in Friction Stir Lap Welding of Al-Mg Dissimilar Alloy[J]. Materials and Mechanical Engineering, 2022, 46(7): 95-102. DOI: 10.11973/jxgccl202207017

Citation:

PDF (1994 KB)

Numerical Simulation of Residual Stress in Friction Stir Lap Welding of Al-Mg Dissimilar Alloy

1. School of Mechanical and Automotive Engineering, Shanghai University of Engineering Science, Shanghai 201620, China;
2. Shanghai Aircraft Manufacturing Co., Ltd., Shanghai 201324, China

More Information

Received Date: March 17, 2021
Revised Date: April 20, 2022

Graphical Abstract

Abstract

Abstract

The sequential thermo-mechanical coupling method was used to establish the model,and through the orthogonal experiment, the effects of welding speed, overlap amount and stirring tool rotation speed of friction stir lap welding on the residual stress of Al-Mg dissimilar alloy were analyzed by ABAQUS software. The optimal process parameters were obtained. The simulation was verified by tests. The effects of welding speed and overlap amount on the residual stress were studied. The results show that the optimal parameters of friction stir lap welding were welding speed of 60 mm·min^-1, overlap amount of 60 mm and stirring tool rotation speed of 1 400 r·min^-1. In different welding processes, the simulation of thermal cycle curves and residual stress were consistent with the experimental results, and the relative errors were less than 7.5% and 8.4%, respectively, which verified the accuracy of the simulation. The maximum residual stress appeared at the overlap surface at the end of the weld, and the maximum longitudinal residual stress in the optimal welding process was 137.7 MPa. Compared with the rotation speed of the stirring tool, the welding speed and the overlap amount had a great influence on the residual stress. With increasing welding speed, the peak value of the longitudinal residual compressive stress increased,and the range of compressive stress became narrower; with increasing overlap amount, the peak value of longitudinal residual compressive stress decreased and the range of compressive stress became wider.
- dissimilar alloy friction stir lap welding,
- residual stress,
- numerical simulation

FullText(HTML)

References (21)

References

[1]	HATTEL J H,SONNE M R,TUTUM C C.Modelling residual stresses in friction stir welding of Al alloys-A review of possibilities and future trends[J].The International Journal of Advanced Manufacturing Technology,2015,76(9/10/11/12):1793-1805.
[2]	陈彦君,朱平,张秀娟,等.6系铝合金板搅拌摩擦焊残余应力有限元分析[J].大连交通大学学报,2019,40(6):93-97. CHEN Y J,ZHU P,ZHANG X J,et al.Finite element analysis of residual stress in friction stir welding of 6 series aluminum alloy plate[J].Journal of Dalian Jiaotong University,2019,40(6):93-97.
[3]	卢翔,邵良臣,韩善灵.钢/铝异种金属搅拌摩擦焊残余应力场分析[J].兵器材料科学与工程,2019,42(5):85-89. LU X,SHAO L C,HAN S L.Analysis of residual stress field of friction stir welding on steel/aluminum dissimilar metals[J].Ordnance Material Science and Engineering,2019,42(5):85-89.
[4]	周文静,许振波,杜柏松.铝合金搅拌摩擦焊温度场及残余应力场研究[J].兵器材料科学与工程,2020,43(3):74-79. ZHOU W J,XU Z B,DU B S.Temperature field and residual stress field of friction stir welding of aluminum alloy[J].Ordnance Material Science and Engineering,2020,43(3):74-79.
[5]	史学海,吕赞,胡云瑞,等.冷-热源辅助对FSW残余应力影响的数值模拟[J].精密成形工程,2020,12(2):55-60. SHI X H,LU Z,HU Y R,et al.Numerical simulation for influence of cold and thermal sources on FSW residual stress[J].Journal of Netshape Forming Engineering,2020,12(2):55-60.
[6]	张昭,谭治军,李健宇,等.铝合金搅拌摩擦搭接焊温度-再结晶-析出相-力学性能一体化数值模拟[J].机械工程学报,2020,56(6):213-220. ZHANG Z,TANG Z J,LI J Y.Integrated numerical simulation of temperature-recrystallization-precipitatemechanical property in friction stir lap welding of aluminum alloy[J].Journal of Mechanical Engineering,2020,56(6):213-220.
[7]	胡云瑞,何兆坤,张利国,等.轴肩形貌对搅拌摩擦搭接焊材料流动与接头成形的影响[J].热加工工艺,2018,47(13):199-202. HU Y R,HE Z K,ZHANG L G,et al.Effect of shoulder geometry on material flow and joint formation of friction stir lap welding[J].Hot Working Technology,2018,47(13):199-202.
[8]	武传松,宿浩,石磊.搅拌摩擦焊接产热传热过程与材料流动的数值模拟[J].金属学报,2018,54(2):265-277. WU C S,SU H,SHI L.Numerical simulation of heat generation,heat transfer and material flow in friction stir welding[J].Acta Metallurgica Sinica,2018,54(2):265-277.
[9]	冯莹莹,赵双,刘照松,等.7075铝合金搅拌摩擦焊模拟与实验研究[J].东北大学学报(自然科学版),2021,42(3):340-346. FENG Y Y,ZHAO S,LIU Z S,et al.Experiment study and simulation for friction stir welding process of 7075 aluminum alloy[J].Journal of Northeastern University (Natural Science),2021,42(3):340-346.
[10]	刘春宁,郁志凯,张艳辉,等.搅拌针几何形状对搅拌摩擦焊温度场的影响[J].焊接技术,2018,47(6):73-76. LIU C Y,YU Z K,ZHANG Y H,et al.Effect of pin shapes on temperature field in friction stir welding[J].Welding Technology,2018,47(6):73-76.
[11]	冯可.纯钛与AZ31B镁合金平板搭接TIG熔钎焊的数值模拟研究[D].重庆:重庆大学,2014. FENG K.Numerical simulations of dissimilar TIG welding-brazing of Titanium and magnesium alloy AZ31B lap joints[D].Chongqing:Chongqing University,2019.
[12]	RIAHI M,NAZARI H.Analysis of transient temperature and residual thermal stresses in friction stir welding of aluminum alloy 6061-T6 via numerical simulation[J].The International Journal of Advanced Manufacturing Technology,2011,55(1/2/3/4):143-152.
[13]	才宇.轨道车辆铝镁合金异种材料FSW仿真研究[D].大连:大连交通大学,2019. CAI Y.Simulation on dissimilar material FSW with Al and Mg alloy for rail vehicles[D].Dalian:Dalian Jiaotong University,2019.
[14]	陈魁.试验设计与分析[M].北京:清华大学出版社,2005. CHEN K.Experimental desing abd analysis[M].Beijing:Tsinghua University Press,2005.
[15]	HE X C,GU F S,BALL A.A review of numerical analysis of friction stir welding[J].Progress in Materials Science,2014,65:1-66.
[16]	MOHARAMI R, SATTARI-FAR I. Experimental and numerical study of measuring high welding residual stresses by using the blind-hole-drilling technique[J]. The Journal of Strain Analysis for Engineering Design, 2008, 43(3):141-148.
[17]	BACHMANN M,CARSTENSEN J,BERGMANN L,et al.Numerical simulation of thermally induced residual stresses in friction stir welding of aluminum alloy 2024-T3 at different welding speeds[J].The International Journal of Advanced Manufacturing Technology,2017,91(1/2/3/4):1443-1452.
[18]	李宁.紫铜与不锈钢搭接搅拌摩擦焊工艺研究及应用[D].长沙:中南大学,2014. LI N.Copper/stainless steel lap joint by friction stir welding process research and application[D].Changsha:Central South University,2014.
[19]	NIE L,WU Y X,GONG H.Prediction of temperature and residual stress distributions in friction stir welding of aluminum alloy[J].The International Journal of Advanced Manufacturing Technology,2020,106(7/8):3301-3310.
[20]	KANG S W,JANG B S,SONG H C.Residual stresses analysis of friction stir welding using one-way FSI simulation[J].Journal of Mechanical Science and Technology,2015,29(3):1111-1121.
[21]	万胜强,吴运新,龚海,等.2219铝合金搅拌摩擦焊温度与残余应力热力耦合模拟[J].热加工工艺,2019,48(13):159-163. WAN S Q,WU Y X,GONG H,et al.Thermal mechanical coupling simulation of temperature and residual stress in friction stir welding of 2219 aluminum alloy[J].Hot Working Technology,2019,48(13):159-163.

Cited By

Get Citation

PDF

XML

Article views (8) PDF downloads (4)

Turn off MathJax

Article Contents

Abstract

References

Numerical Simulation of Residual Stress in Friction Stir Lap Welding of Al-Mg Dissimilar Alloy

Abstract

References

Catalog

Export File

Citation

Format

Content