Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

Gupta, Varun; Upadhyay, Piyush; Fifield, Leonard S.; Roosendaal, Timothy; Sun, Xin; Nelaturu, Phalgun; Carlson, Blair

doi:10.1016/j.jmapro.2018.03.030

Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

Journal Article · 01 April 2018 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2018.03.030· OSTI ID:1491237

; Upadhyay, Piyush; Fifield, Leonard S.; Roosendaal, Timothy; Sun, Xin; Nelaturu, Phalgun; Carlson, Blair

The friction stir welding (FSW) is a popular technique to join dissimilar materials in numerous applications. The solid state nature of the process enables joining materials with strikingly different physical properties. For the welds in lap configuration, an enhancement to this technology is made by introducing a short hard insert, referred to as cutting-scribe, at the bottom of the tool pin. The cutting-scribe induces deformation in the bottom plate which leads to the formation of mechanical interlocks or hook like structures at the interface of two materials. A thermo-mechanically coupled computational model employing coupled Eulerian-Lagrangian approach is developed to quantitatively capture the morphology of these interlocks during the FSW process. The simulations using developed model are validated by the experimental observations.The identified interface morphology coupled with the predicted temperature field from this process-structure model can then be used to estimate the post-weld microstructure and joint strength.

Research Organization:: Pacific Northwest National Lab. (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE

DOE Contract Number:: AC05-76RL01830

OSTI ID:: 1491237

Report Number(s):: PNNL-SA-129173

Journal Information:: Journal of Manufacturing Processes, Vol. 32, Issue C; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; Elsevier

Country of Publication:: United States

Language:: English

References (40)

Dissimilar friction stir welds in AA5083-AA6082. Part I: Process parameter effects on thermal history and weld properties No authors listed Metallurgical and Materials Transactions A https://doi.org/10.1007/BF02586138		July 2006
Peak temperatures and microstructures in aluminium and magnesium alloy friction stir spot welds No authors listed Science and Technology of Welding and Joining https://doi.org/10.1179/174329305X48383		December 2005
Constitutional liquation during dissimilar friction stir welding of Al and Mg alloys No authors listed Scripta Materialia https://doi.org/10.1016/j.scriptamat.2004.02.002		May 2004
Joining of Al 6061 alloy to AISI 1018 steel by combined effects of fusion and solid state welding No authors listed International Journal of Machine Tools and Manufacture https://doi.org/10.1016/j.ijmachtools.2004.03.011		September 2004
Friction stir welding of dissimilar Al 6013-T4 To X5CrNi18-10 stainless steel No authors listed Materials & Design https://doi.org/10.1016/j.matdes.2004.04.002		February 2005
Interfacial reaction in steel–aluminum joints made by friction stir welding No authors listed Scripta Materialia https://doi.org/10.1016/j.scriptamat.2006.04.028		August 2006
Joining of aluminum alloy to steel by friction stir welding No authors listed Journal of Materials Processing Technology https://doi.org/10.1016/j.jmatprotec.2006.04.117		September 2006
Effect of lap configuration on magnesium to aluminum friction stir lap welding assisted by external stationary shoulder No authors listed Materials & Design https://doi.org/10.1016/j.matdes.2016.04.066		August 2016
Microstructure and Properties of Friction Stir Lap Welded Dissimilar Magnesium Alloy No authors listed Journal of Computational and Theoretical Nanoscience https://doi.org/10.1166/jctn.2015.4211		September 2015
Dissimilar material joining using laser (aluminum to steel using zinc-based filler wire) No authors listed Optics & Laser Technology https://doi.org/10.1016/j.optlastec.2005.08.014		April 2007
Welding and Joining of Titanium Aluminides No authors listed Materials https://doi.org/10.3390/ma7074930		June 2014
Joining of SiO ₂ –BN ceramic to Nb using a CNT-reinforced brazing alloy No authors listed RSC Adv. https://doi.org/10.1039/C4RA11110A		January 2014
Friction stir welding: Process, automation, and control No authors listed Journal of Manufacturing Processes https://doi.org/10.1016/j.jmapro.2013.04.002		January 2014
Friction stir welding of aluminium alloys No authors listed International Materials Reviews https://doi.org/10.1179/174328009X411136		March 2009
Friction stir welding and processing No authors listed Materials Science and Engineering: R: Reports https://doi.org/10.1016/j.mser.2005.07.001		August 2005
Recent advances in friction-stir welding – Process, weldment structure and properties No authors listed Progress in Materials Science https://doi.org/10.1016/j.pmatsci.2008.05.001		August 2008
Numerical simulation of temperature field and residual stress in multi-pass welds in stainless steel pipe and comparison with experimental measurements No authors listed Computational Materials Science https://doi.org/10.1016/j.commatsci.2005.07.007		September 2006
An analytical model for the heat generation in friction stir welding No authors listed Modelling and Simulation in Materials Science and Engineering https://doi.org/10.1088/0965-0393/12/1/013		November 2003
Thermal modelling of friction stir welding No authors listed Scripta Materialia https://doi.org/10.1016/j.scriptamat.2007.10.008		March 2008
Prediction of temperature distribution and thermal history during friction stir welding: input torque based model No authors listed Science and Technology of Welding and Joining https://doi.org/10.1179/136217103225010943		June 2003
Thermal modeling of friction stir welding of stainless steel 304L No authors listed The International Journal of Advanced Manufacturing Technology https://doi.org/10.1007/s00170-014-6203-y		August 2014
Thermal modeling of friction stir welding in a moving coordinate system and its validation No authors listed International Journal of Machine Tools and Manufacture https://doi.org/10.1016/S0890-6955(03)00022-1		May 2003
Developing Friction Stir Welding Process Model for ICME Application No authors listed Journal of Materials Engineering and Performance https://doi.org/10.1007/s11665-014-1260-9		October 2014
Integrated modeling of friction stir welding of 6xxx series Al alloys: Process, microstructure and properties No authors listed Progress in Materials Science https://doi.org/10.1016/j.pmatsci.2011.05.003		January 2012
Thermo-mechanical finite element model of friction stir welding of dissimilar alloys No authors listed The International Journal of Advanced Manufacturing Technology https://doi.org/10.1007/s00170-014-5680-3		February 2014
Finite element modeling of friction stir welding—thermal and thermomechanical analysis No authors listed International Journal of Machine Tools and Manufacture https://doi.org/10.1016/S0890-6955(03)00158-5		October 2003
Thermo-mechanical model with adaptive boundary conditions for friction stir welding of Al 6061 No authors listed International Journal of Machine Tools and Manufacture https://doi.org/10.1016/j.ijmachtools.2005.02.008		November 2005
Three-dimensional modeling of the friction stir-welding process No authors listed International Journal of Machine Tools and Manufacture https://doi.org/10.1016/S0890-6955(02)00114-1		November 2002
Finite element simulation of material flow in friction stir welding No authors listed Science and Technology of Welding and Joining https://doi.org/10.1179/136217101101538640		June 2001
Coupled Eulerian Lagrangian finite element modeling of friction stir welding processes No authors listed Journal of Materials Processing Technology https://doi.org/10.1016/j.jmatprotec.2013.02.014		August 2013
Numerical modeling of friction stir welding processes No authors listed Computer Methods in Applied Mechanics and Engineering https://doi.org/10.1016/j.cma.2012.09.013		February 2013
A simple and robust moving mesh technique for the finite element simulation of Friction Stir Welding No authors listed Journal of Computational and Applied Mathematics https://doi.org/10.1016/j.cam.2012.07.013		July 2013
On material flow in Friction Stir Welded Al alloys No authors listed Journal of Materials Processing Technology https://doi.org/10.1016/j.jmatprotec.2016.08.030		January 2017
Explicit coupled thermo-mechanical finite element model of steel solidification No authors listed International Journal for Numerical Methods in Engineering https://doi.org/10.1002/nme.2476		April 2009
Arbitrary Lagrangian–Eulerian finite element simulation and experimental investigation of wavy interfacial morphology during high velocity impact welding No authors listed Materials & Design https://doi.org/10.1016/j.matdes.2015.09.005		December 2015
A new smoothed particle hydrodynamics non-Newtonian model for friction stir welding: Process modeling and simulation of microstructure evolution in a magnesium alloy No authors listed International Journal of Plasticity https://doi.org/10.1016/j.ijplas.2013.02.013		September 2013
Numerical modeling of friction stir welding process: a literature review No authors listed The International Journal of Advanced Manufacturing Technology https://doi.org/10.1007/s00170-012-4154-8		May 2012
A review of numerical analysis of friction stir welding No authors listed Progress in Materials Science https://doi.org/10.1016/j.pmatsci.2014.03.003		August 2014
Computational methods in Lagrangian and Eulerian hydrocodes No authors listed Computer Methods in Applied Mechanics and Engineering https://doi.org/10.1016/0045-7825(92)90042-I		September 1992
Contact in a multi-material Eulerian finite element formulation No authors listed Computer Methods in Applied Mechanics and Engineering https://doi.org/10.1016/j.cma.2003.12.061		October 2004

Cited By (2)

A review on friction-based joining of dissimilar aluminum–steel joints No authors listed Journal of Materials Research https://doi.org/10.1557/jmr.2018.332		October 2018
Effect of Tool Design and Process Parameters on Lap Joints Made by Right Angle Friction Stir Welding (RAFSW) No authors listed Journal of Manufacturing and Materials Processing https://doi.org/10.3390/jmmp3030066		August 2019

Similar Records

Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

Journal Article · 2018 · Journal of Manufacturing Processes · OSTI ID:1434847

Gupta, Varun; Upadhyay, Piyush; Fifield, Leonard S.; +4 more

Friction stir scribe welding technique for dissimilar joining of aluminium and galvanised steel

Journal Article · 2017 · Science and Technology of Welding and Joining · OSTI ID:1422294

Wang, Tianhao; Sidhar, Harpreet; Mishra, Rajiv S.; +3 more

Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

Journal Article · 2018 · Journal of Manufacturing Processes · OSTI ID:1435194

Gupta, Varun; Upadhyay, Piyush; Fifield, Leonard S.; +4 more

Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

Citation Formats

References (40)

Cited By (2)

Similar Records

Related Subjects