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

We present that 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 welds in lap configuration, an enhancement to this technology is made by introducing a short, hard insert, referred to as a 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-mechanical computational model employing a coupled Eulerian-Lagrangian approach is developed to quantitatively capture the morphology of these interlocks during the FSW process. Simulations using this model are validated by experimental observations. In conclusion, the identified interface morphology coupled with the predicted temperature field from this process–structure model can be used to estimate the post-weld microstructure and joint strength.
Authors:
ORCiD logo [1] ;  [1] ;  [1] ;  [2] ;  [2] ;  [3] ;  [3]
  1. Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  3. General Motors Research and Development, Warren, MI (United States)
Publication Date:
Grant/Contract Number:
AC05-00OR22725; AC05-76RL01830; EE0007311
Type:
Accepted Manuscript
Journal Name:
Journal of Manufacturing Processes
Additional Journal Information:
Journal Volume: 32; Journal Issue: C; Journal ID: ISSN 1526-6125
Publisher:
Society of Manufacturing Engineers; Elsevier
Research Org:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; 36 MATERIALS SCIENCE; Coupled Eulerian-Lagrangian; Solid-state joining; Finite Element Method
OSTI Identifier:
1435194

Gupta, Varun, Upadhyay, Piyush, Fifield, Leonard S., Roosendaal, Timothy, Sun, Xin, Nelaturu, Phalgun, and Carlson, Blair. Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support. United States: N. p., Web. doi:10.1016/j.jmapro.2018.03.030.
Gupta, Varun, Upadhyay, Piyush, Fifield, Leonard S., Roosendaal, Timothy, Sun, Xin, Nelaturu, Phalgun, & Carlson, Blair. Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support. United States. doi:10.1016/j.jmapro.2018.03.030.
Gupta, Varun, Upadhyay, Piyush, Fifield, Leonard S., Roosendaal, Timothy, Sun, Xin, Nelaturu, Phalgun, and Carlson, Blair. 2018. "Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support". United States. doi:10.1016/j.jmapro.2018.03.030.
@article{osti_1435194,
title = {Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support},
author = {Gupta, Varun and Upadhyay, Piyush and Fifield, Leonard S. and Roosendaal, Timothy and Sun, Xin and Nelaturu, Phalgun and Carlson, Blair},
abstractNote = {We present that 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 welds in lap configuration, an enhancement to this technology is made by introducing a short, hard insert, referred to as a 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-mechanical computational model employing a coupled Eulerian-Lagrangian approach is developed to quantitatively capture the morphology of these interlocks during the FSW process. Simulations using this model are validated by experimental observations. In conclusion, the identified interface morphology coupled with the predicted temperature field from this process–structure model can be used to estimate the post-weld microstructure and joint strength.},
doi = {10.1016/j.jmapro.2018.03.030},
journal = {Journal of Manufacturing Processes},
number = C,
volume = 32,
place = {United States},
year = {2018},
month = {4}
}