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Title: Modeling of Residual Stresses and Property Distributions in Friction Stir Welds of Aluminum Alloy 6061-T6

Abstract

An integrated thermal-metallurgical-mechanical model is used to analyze and provide insights into the formation of the residual stress and the changes in microstructure and property of Al6061-T6 friction stir welds. The simulations were conducted by means of a three-dimensional finite element model that accounts for the phenomena of frictional heating, weld microstructure and strength changes due to dissolution and reprecipitation of the hardening precipitate particles, and the mechanical workpiece/tool contact during the friction stir welding (FSW) process. The model predictions were confirmed by experimental measurement data from previous studies. For the friction stir welds investigated, it was found that the residual stress distribution is strongly dependent on the welding process parameters and the degree of material softening caused by welding. The recovery of material strength from natural aging does not increase the residual stress in the weld. The failure of friction stir weld under tensile load is controlled by the combination of the reduction in strength and the residual stresses in the heat affected zone (HAZ).

Authors:
 [1];  [1];  [1];  [1]
  1. ORNL
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); High Flux Isotope Reactor
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
931698
DOE Contract Number:
DE-AC05-00OR22725
Resource Type:
Journal Article
Resource Relation:
Journal Name: Science and Technology of Welding and Joining; Journal Volume: 12; Journal Issue: 4
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; ALUMINIUM BASE ALLOYS; MATHEMATICAL MODELS; WELDED JOINTS; MORPHOLOGICAL CHANGES; FRICTION; HEAT AFFECTED ZONE; MICROSTRUCTURE; RESIDUAL STRESSES; FINITE ELEMENT METHOD

Citation Formats

Feng, Zhili, David, Stan A, Wang, Xun-Li, and Sklad, Philip S. Modeling of Residual Stresses and Property Distributions in Friction Stir Welds of Aluminum Alloy 6061-T6. United States: N. p., 2007. Web. doi:10.1179/174329307X197610.
Feng, Zhili, David, Stan A, Wang, Xun-Li, & Sklad, Philip S. Modeling of Residual Stresses and Property Distributions in Friction Stir Welds of Aluminum Alloy 6061-T6. United States. doi:10.1179/174329307X197610.
Feng, Zhili, David, Stan A, Wang, Xun-Li, and Sklad, Philip S. Mon . "Modeling of Residual Stresses and Property Distributions in Friction Stir Welds of Aluminum Alloy 6061-T6". United States. doi:10.1179/174329307X197610.
@article{osti_931698,
title = {Modeling of Residual Stresses and Property Distributions in Friction Stir Welds of Aluminum Alloy 6061-T6},
author = {Feng, Zhili and David, Stan A and Wang, Xun-Li and Sklad, Philip S},
abstractNote = {An integrated thermal-metallurgical-mechanical model is used to analyze and provide insights into the formation of the residual stress and the changes in microstructure and property of Al6061-T6 friction stir welds. The simulations were conducted by means of a three-dimensional finite element model that accounts for the phenomena of frictional heating, weld microstructure and strength changes due to dissolution and reprecipitation of the hardening precipitate particles, and the mechanical workpiece/tool contact during the friction stir welding (FSW) process. The model predictions were confirmed by experimental measurement data from previous studies. For the friction stir welds investigated, it was found that the residual stress distribution is strongly dependent on the welding process parameters and the degree of material softening caused by welding. The recovery of material strength from natural aging does not increase the residual stress in the weld. The failure of friction stir weld under tensile load is controlled by the combination of the reduction in strength and the residual stresses in the heat affected zone (HAZ).},
doi = {10.1179/174329307X197610},
journal = {Science and Technology of Welding and Joining},
number = 4,
volume = 12,
place = {United States},
year = {Mon Jan 01 00:00:00 EST 2007},
month = {Mon Jan 01 00:00:00 EST 2007}
}