NUMERICAL SIMULATION OF DISSIMILAR FRICTION STIR WELDING OF ALUMINUM ALLOYS AA7075 AND AA2024: INFLUENCE OF TOOL GEOMETRY ON TEMPERATURE DISTRIBUTION

Alexandru Ionuț TOMA, Younes DEMMOUCHE, Matthieu DHONDT, Claudiu BĂDULESCU, Eduard Laurențiu NIȚU, Daniela Monica IORDACHE

Abstract


Friction Stir Welding (FSW) is an innovative joining process widely applied for aluminum alloys, offering low-cost and efficient solutions for complex industrial applications. This study focuses on welding dissimilar aluminum alloys AA7075 and AA2024, emphasizing the importance of temperature control and the influence of tool geometry on the process. Numerical modeling was performed Abaqus software to simulate the thermal behavior during welding and analyze key parameters such as pin profile and coefficient of friction. The results reveal that the cylindrical threaded pin generates moderate temperatures, making it most suitable for welding these alloys, while the square pin produces higher temperatures, posing a risk of overheating, particularly for AA7075. In contrast, conical and cylindrical pins generate insufficient heat for effective joint formation. This research highlights the value of numerical simulations in optimizing FSW parameters for defect-free joints in dissimilar aluminum alloys.

References


Guo, Y., Ma, Y., Zhang, X., Qian, X., Li, J., Study on residual stress distribution of 2024-T3 and 7075-T6 aluminum dissimilar friction stir welded joints, Eng Fail Anal, vol. 118, 2020.

Niu, P. et al., Strengthening mechanisms of pre-stretching strain on friction stir welded 2024-to-7075 dissimilar aluminum alloys joints: Yield sequence effect, Mater Charact, vol. 211, 2024.

Niu, P., Li, W., Yang, C., Chen, Y., Chen, D., Low cycle fatigue properties of friction stir welded dissimilar 2024-to-7075 aluminum alloy joints, Materials Science and Engineering A, vol. 832, 2022.

Kumar Choudhary, A., Jain, R., Investigation of the influence of defect volume on weld strength during FSW: A simulation and experimental study, Eng Fail Anal, vol. 162, 2024.

Kumar Dewangan, S., Kumar Tripathi, M., Nandan Banjare, P., Kumar Manoj, M., Temperature Distribution of Friction Stir Welded Al 7075 alloy using Finite Element Simulation along with Experimental Validation, Mater Today Proc, 2023.

Wu, C., Wang, J., Wang, Q., Xia, P., Li, D., 7075 aluminum alloy Friction Stir Welding (FSW): Quality analysis and mechanical properties with WC-Co tool, Mater Today Commun, vol. 38, 2024.

Jacquin, D., Guillemot, G., Gildas, G., A review of microstructural changes occurring during FSW in aluminium alloys and their modelling, J Mater Process Technol, vol. 288, 2021.

Sambasivam, S. et al., A review paper of FSW on dissimilar materials using aluminum, Mater Today Proc, 2023.

Mijajlovic, M., Milcic, D., Milcic, M., Numerical simulation of friction stir welding, Thermal Science, vol. 18, no. 3, pp. 967–978, 2014.

Rathinasuriyan, C., Puviyarasan, M., Sankar, R., Selvakumar, V., Effect of process parameters on weld geometry and mechanical properties in friction stir welding of AA2024 and AA7075 alloys, Journal of Alloys and Metallurgical Systems, vol. 7. 2024.

Akbari, M., Rahimi Asiabaraki, H., Hassanzadeh, E., Esfandiar, M., Simulation of dissimilar friction stir welding of AA7075 and AA5083 aluminium alloys using Coupled Eulerian–Lagrangian approach, Welding International, vol. 37, no. 4, pp. 174–184, 2023.

Kumar Yadav, B., Singh Bhadauria, S., Sharma, V., A review on fracture and fatigue behaviour of FSW joints of Al alloys, Mater Today Proc, 2023.

Hosseini, A., Arezoudar, A.F., Modified CEL method for determination of defect formation mechanism in underwater stationary FSW based on softened pressure-overclosure contact relationship, Forces in Mechanics, vol. 17, 2024.

Daniyan, I., Mpofu, K., Ramatsetse, B., Phuluwa, H.S., Numerical modeling and validation of Aluminium Friction Stir Welding (FSW) process during railcar manufacturing, Procedia CIRP, Elsevier, pp. 7–14, 2020.

Iordache, M.D. et al., A numerical strategy to identify the FSW process optimal parameters of a butt-welded joint of quasi-pure copper plates: modeling and experimental validation, International Journal of Advanced Manufacturing Technology, vol. 115, no. 7–8, pp. 2505–2520, 2021.

Nirmal, K., Jagadesh, T., Numerical simulations of friction stir welding of dual phase titanium alloy for aerospace applications, Mater Today Proc, vol. 46, pp. 4702–4708, 2019.

Li, W., Shi, S., Wang, F., Zhang, Z., Ma, T., Li, J., Numerical simulation of friction welding processes based on ABAQUS environment, Journal of Engineering Science and Technology Review, vol. 5, no. 3, pp. 10–19, 2012.

Sibalic, N., Vukcevic, M., Numerical simulation for FSW process at welding aluminium alloy aa6082-t6, Metals (Basel), vol. 9, no. 7, 2019.

Roy, B.S., Saha, S.C., DebBarma, J., 3D modeling & numerical simulation of Friction Stir welding process, Adv Mat Res, vol. 488–489, pp. 1189–1193, 2012.

Guedir, A., Contribution à la modélisation et à la simulation numérique du soudage par friction et malaxage. Available: https://pastel.archives-ouvertes.fr/pastel-00842393

Eyvazian, A., Hamouda, A., Tarlochan, F., Derazkola, H.A., Khodabakhshi, F., Simulation and experimental study of underwater dissimilar friction-stir welding between aluminium and steel, Journal of Materials Research and Technology, vol. 9, no. 3, pp. 3767–3781, 2020.

Wu, C.S., Bin Zhang, W., Shi, L., Chen, M. A., Visualization and simulation of plastic material flow in friction stir welding of 2024 aluminium alloy plates, Transactions of Nonferrous Metals Society of China (English Edition), vol. 22, no. 6, pp. 1445–1451, 2012.

Mishin, V. et al., Numerical Simulation of the Thermo-Mechanical Behavior of 6061 Aluminum Alloy during Friction-Stir Welding, Journal of Manufacturing and Materials Processing, vol. 6, no. 4, 2022.

Langari, J., Aliakbari, K., Kolahan, F., Fatigue life simulation of AA7075-T651 FSW joints using experimental data, Eng Fail Anal, vol. 154, 2023.


Refbacks

  • There are currently no refbacks.


JOURNAL INDEXED IN :