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 · Sun Apr 01 00:00:00 EDT 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 Laboratory (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, Journal Name: Journal of Manufacturing Processes Journal Issue: C Vol. 32; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; Elsevier

Country of Publication:: United States

Language:: English

References (40)

Thermal modelling of friction stir welding Schmidt, H. B.; Hattel, J. H. Scripta Materialia, Vol. 58, Issue 5 https://doi.org/10.1016/j.scriptamat.2007.10.008	journal	March 2008
Thermo-mechanical finite element model of friction stir welding of dissimilar alloys Al-Badour, Fadi; Merah, Nesar; Shuaib, Abdelrahman The International Journal of Advanced Manufacturing Technology, Vol. 72, Issue 5-8 https://doi.org/10.1007/s00170-014-5680-3	journal	February 2014
Dissimilar material joining using laser (aluminum to steel using zinc-based filler wire) Mathieu, Alexandre; Shabadi, Rajashekar; Deschamps, Alexis Optics & Laser Technology, Vol. 39, Issue 3 https://doi.org/10.1016/j.optlastec.2005.08.014	journal	April 2007
Peak temperatures and microstructures in aluminium and magnesium alloy friction stir spot welds Gerlich, A.; Su, P.; North, T. H. Science and Technology of Welding and Joining, Vol. 10, Issue 6 https://doi.org/10.1179/174329305X48383	journal	December 2005
Prediction of temperature distribution and thermal history during friction stir welding: input torque based model Khandkar, M. Z. H.; Khan, J. A.; Reynolds, A. P. Science and Technology of Welding and Joining, Vol. 8, Issue 3 https://doi.org/10.1179/136217103225010943	journal	June 2003
Effect of lap configuration on magnesium to aluminum friction stir lap welding assisted by external stationary shoulder Ji, Shude; Li, Zhengwei; Zhang, Liguo Materials & Design, Vol. 103 https://doi.org/10.1016/j.matdes.2016.04.066	journal	August 2016
Joining of Al 6061 alloy to AISI 1018 steel by combined effects of fusion and solid state welding Chen, C. M.; Kovacevic, R. International Journal of Machine Tools and Manufacture, Vol. 44, Issue 11 https://doi.org/10.1016/j.ijmachtools.2004.03.011	journal	September 2004
Numerical modeling of friction stir welding processes Chiumenti, M.; Cervera, M.; Agelet de Saracibar, C. Computer Methods in Applied Mechanics and Engineering, Vol. 254 https://doi.org/10.1016/j.cma.2012.09.013	journal	February 2013
Friction stir welding: Process, automation, and control Gibson, B. T.; Lammlein, D. H.; Prater, T. J. Journal of Manufacturing Processes, Vol. 16, Issue 1 https://doi.org/10.1016/j.jmapro.2013.04.002	journal	January 2014
Finite element modeling of friction stir welding—thermal and thermomechanical analysis Chen, C. M.; Kovacevic, R. International Journal of Machine Tools and Manufacture, Vol. 43, Issue 13 https://doi.org/10.1016/S0890-6955(03)00158-5	journal	October 2003
Arbitrary Lagrangian–Eulerian finite element simulation and experimental investigation of wavy interfacial morphology during high velocity impact welding Nassiri, Ali; Chini, Greg; Vivek, Anupam Materials & Design, Vol. 88 https://doi.org/10.1016/j.matdes.2015.09.005	journal	December 2015
Joining of SiO ₂ –BN ceramic to Nb using a CNT-reinforced brazing alloy Qi, Jun Lei; Lin, Jing Huang; Wan, Yu Han RSC Adv., Vol. 4, Issue 109 https://doi.org/10.1039/C4RA11110A	journal	January 2014
Friction stir welding of aluminium alloys Threadgill, P. L.; Leonard, A. J.; Shercliff, H. R. International Materials Reviews, Vol. 54, Issue 2 https://doi.org/10.1179/174328009X411136	journal	March 2009
Finite element simulation of material flow in friction stir welding Xu, S.; deng, X.; Reynolds, A. P. Science and Technology of Welding and Joining, Vol. 6, Issue 3 https://doi.org/10.1179/136217101101538640	journal	June 2001
Thermo-mechanical model with adaptive boundary conditions for friction stir welding of Al 6061 Soundararajan, Vijay; Zekovic, Srdja; Kovacevic, Radovan International Journal of Machine Tools and Manufacture, Vol. 45, Issue 14 https://doi.org/10.1016/j.ijmachtools.2005.02.008	journal	November 2005
Numerical simulation of temperature field and residual stress in multi-pass welds in stainless steel pipe and comparison with experimental measurements Deng, Dean; Murakawa, Hidekazu Computational Materials Science, Vol. 37, Issue 3 https://doi.org/10.1016/j.commatsci.2005.07.007	journal	September 2006
Microstructure and Properties of Friction Stir Lap Welded Dissimilar Magnesium Alloy Li, Tielong; Wang, Zhenshan; Qu, Erguang Journal of Computational and Theoretical Nanoscience, Vol. 12, Issue 9 https://doi.org/10.1166/jctn.2015.4211	journal	September 2015
A simple and robust moving mesh technique for the finite element simulation of Friction Stir Welding Feulvarch, E.; Roux, J. -C.; Bergheau, J. -M. Journal of Computational and Applied Mathematics, Vol. 246 https://doi.org/10.1016/j.cam.2012.07.013	journal	July 2013
Explicit coupled thermo-mechanical finite element model of steel solidification Koric, Seid; Hibbeler, Lance C.; Thomas, Brian G. International Journal for Numerical Methods in Engineering, Vol. 78, Issue 1 https://doi.org/10.1002/nme.2476	journal	April 2009
Thermal modeling of friction stir welding of stainless steel 304L Darvazi, Armin Rahmati; Iranmanesh, Mehdi The International Journal of Advanced Manufacturing Technology, Vol. 75, Issue 9-12 https://doi.org/10.1007/s00170-014-6203-y	journal	August 2014
Welding and Joining of Titanium Aluminides Cao, Jian; Qi, Junlei; Song, Xiaoguo Materials, Vol. 7, Issue 7 https://doi.org/10.3390/ma7074930	journal	June 2014
Integrated modeling of friction stir welding of 6xxx series Al alloys: Process, microstructure and properties Simar, A.; Bréchet, Y.; de Meester, B. Progress in Materials Science, Vol. 57, Issue 1 https://doi.org/10.1016/j.pmatsci.2011.05.003	journal	January 2012
Friction stir welding and processing Mishra, R. S.; Ma, Z. Y. Materials Science and Engineering: R: Reports, Vol. 50, Issue 1-2 https://doi.org/10.1016/j.mser.2005.07.001	journal	August 2005
Thermal modeling of friction stir welding in a moving coordinate system and its validation Song, M.; Kovacevic, R. International Journal of Machine Tools and Manufacture, Vol. 43, Issue 6 https://doi.org/10.1016/S0890-6955(03)00022-1	journal	May 2003
Interfacial reaction in steel–aluminum joints made by friction stir welding Lee, Won-Bae; Schmuecker, Martin; Mercardo, Ulises Alfaro Scripta Materialia, Vol. 55, Issue 4 https://doi.org/10.1016/j.scriptamat.2006.04.028	journal	August 2006
Recent advances in friction-stir welding – Process, weldment structure and properties Nandan, R.; Debroy, T.; Bhadeshia, H. Progress in Materials Science, Vol. 53, Issue 6 https://doi.org/10.1016/j.pmatsci.2008.05.001	journal	August 2008
Computational methods in Lagrangian and Eulerian hydrocodes Benson, David J. Computer Methods in Applied Mechanics and Engineering, Vol. 99, Issue 2-3 https://doi.org/10.1016/0045-7825(92)90042-I	journal	September 1992
Coupled Eulerian Lagrangian finite element modeling of friction stir welding processes Al-Badour, Fadi; Merah, Nesar; Shuaib, Abdelrahman Journal of Materials Processing Technology, Vol. 213, Issue 8 https://doi.org/10.1016/j.jmatprotec.2013.02.014	journal	August 2013
Contact in a multi-material Eulerian finite element formulation Benson, David J.; Okazawa, Shigenobu Computer Methods in Applied Mechanics and Engineering, Vol. 193, Issue 39-41 https://doi.org/10.1016/j.cma.2003.12.061	journal	October 2004
An analytical model for the heat generation in friction stir welding Schmidt, H.; Hattel, J.; Wert, J. Modelling and Simulation in Materials Science and Engineering, Vol. 12, Issue 1 https://doi.org/10.1088/0965-0393/12/1/013	journal	November 2003
Developing Friction Stir Welding Process Model for ICME Application Yang, Yu-Ping Journal of Materials Engineering and Performance, Vol. 24, Issue 1 https://doi.org/10.1007/s11665-014-1260-9	journal	October 2014
Friction stir welding of dissimilar Al 6013-T4 To X5CrNi18-10 stainless steel Uzun, Huseyin; Dalle Donne, Claudio; Argagnotto, Alberto Materials & Design, Vol. 26, Issue 1 https://doi.org/10.1016/j.matdes.2004.04.002	journal	February 2005
Dissimilar friction stir welds in AA5083-AA6082. Part I: Process parameter effects on thermal history and weld properties Peel, M. J.; Steuwer, A.; Withers, P. J. Metallurgical and Materials Transactions A, Vol. 37, Issue 7 https://doi.org/10.1007/BF02586138	journal	July 2006
Joining of aluminum alloy to steel by friction stir welding Watanabe, Takehiko; Takayama, Hirofumi; Yanagisawa, Atsushi Journal of Materials Processing Technology, Vol. 178, Issue 1-3 https://doi.org/10.1016/j.jmatprotec.2006.04.117	journal	September 2006
A review of numerical analysis of friction stir welding He, Xiaocong; Gu, Fengshou; Ball, Andrew Progress in Materials Science, Vol. 65 https://doi.org/10.1016/j.pmatsci.2014.03.003	journal	August 2014
Three-dimensional modeling of the friction stir-welding process Ulysse, P. International Journal of Machine Tools and Manufacture, Vol. 42, Issue 14 https://doi.org/10.1016/S0890-6955(02)00114-1	journal	November 2002
Constitutional liquation during dissimilar friction stir welding of Al and Mg alloys Sato, Yutaka S.; Park, Seung Hwan C.; Michiuchi, Masato Scripta Materialia, Vol. 50, Issue 9 https://doi.org/10.1016/j.scriptamat.2004.02.002	journal	May 2004
A new smoothed particle hydrodynamics non-Newtonian model for friction stir welding: Process modeling and simulation of microstructure evolution in a magnesium alloy Pan, Wenxiao; Li, Dongsheng; Tartakovsky, Alexandre M. International Journal of Plasticity, Vol. 48 https://doi.org/10.1016/j.ijplas.2013.02.013	journal	September 2013
Numerical modeling of friction stir welding process: a literature review Neto, Diogo Mariano; Neto, Pedro The International Journal of Advanced Manufacturing Technology, Vol. 65, Issue 1-4 https://doi.org/10.1007/s00170-012-4154-8	journal	May 2012
On material flow in Friction Stir Welded Al alloys Tongne, A.; Desrayaud, C.; Jahazi, M. Journal of Materials Processing Technology, Vol. 239 https://doi.org/10.1016/j.jmatprotec.2016.08.030	journal	January 2017

Cited By (2)

Effect of Tool Design and Process Parameters on Lap Joints Made by Right Angle Friction Stir Welding (RAFSW) Momeni, Mahboubeh; Guillot, Michel Journal of Manufacturing and Materials Processing, Vol. 3, Issue 3 https://doi.org/10.3390/jmmp3030066	journal	August 2019
A review on friction-based joining of dissimilar aluminum–steel joints Mehta, Kush P. Journal of Materials Research, Vol. 34, Issue 1 https://doi.org/10.1557/jmr.2018.332	journal	October 2018

Similar Records

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

Journal Article · Sun Apr 01 00:00:00 EDT 2018 · Journal of Manufacturing Processes · OSTI ID:1434847

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

Journal Article · Wed Apr 04 00:00:00 EDT 2018 · Journal of Manufacturing Processes · OSTI ID:1435194

FRICTION STIR LAP WELDING OF ALUMINUM - POLYMER USING SCRIBE TECHNOLOGY

Conference · Sun Feb 15 23:00:00 EST 2015 · OSTI ID:1214902

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