Meshfree simulation and experimental validation of extreme thermomechanical conditions in friction stir extrusion

Li, Lei; Gupta, Varun; Li, Xiao; Reynolds, Anthony P.; Grant, Glenn; Soulami, Ayoub

doi:10.1007/s40571-021-00445-7

Title: Meshfree simulation and experimental validation of extreme thermomechanical conditions in friction stir extrusion

Journal Article · 31 October 2021 · Computational Particle Mechanics

DOI: https://doi.org/10.1007/s40571-021-00445-7 · OSTI ID:1828490

; Gupta, Varun; Li, Xiao; Reynolds, Anthony P.; Grant, Glenn;

Abstract Friction stir extrusion (FSE) is a novel solid-phase processing technique that consolidates and extrudes metal powders, flakes, chips, or billets into high-performance parts by plastic deformation, which has the potential to save substantial processing time and energy. Currently, most studies on FSE are experimental and only a few numerical models have been developed to explain and predict the complex physics of the process. In this work, a meshfree simulation framework based on smoothed particle hydrodynamics (SPH) was developed for FSE. Unlike traditional grid-based methods, SPH is a Lagrangian particle-based method that can handle severe material deformations, capture moving interfaces and surfaces, and monitor the field variable histories explicitly without complicated tracking schemes. These aspects of SPH make it attractive for the FSE process, where in situ evolution of field variables is difficult to observe experimentally. To this end, a 3-D, fully thermomechanically coupled SPH model was developed to simulate the FSE of aluminum wires. The developed model was thoroughly validated by comparing the numerically predicted material flow, strain, temperature history, and extrusion force with experimental results for a certain set of process parameters. The validated SPH model can serve as an effective tool to predict and better understand the extreme thermomechanical conditions during the FSE process.

View Journal Article

Cite

Export

Save

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 1828490

Alternate ID(s):: OSTI ID: 1872975; OSTI ID: 1872981

Journal Information:: Computational Particle Mechanics, Journal Name: Computational Particle Mechanics Journal Issue: 4 Vol. 9; ISSN 2196-4378

Publisher:: Springer Science + Business MediaCopyright Statement

Country of Publication:: Switzerland

Language:: English

References (54)

An apropos kinematic framework for the numerical modeling of friction stir welding Dialami, Narges; Chiumenti, Michele; Cervera, Miguel Computers & Structures, Vol. 117 https://doi.org/10.1016/J.COMPSTRUC.2012.12.006	journal	February 2013
Friction model for friction stir welding process simulation: Calibrations from welding experiments Assidi, Mohamed; Fourment, Lionel; Guerdoux, Simon International Journal of Machine Tools and Manufacture, Vol. 50, Issue 2 https://doi.org/10.1016/j.ijmachtools.2009.11.008	journal	February 2010
Modelling of metal forging using SPH Cleary, Paul W.; Prakash, Mahesh; Das, Raj Applied Mathematical Modelling, Vol. 36, Issue 8 https://doi.org/10.1016/j.apm.2011.11.019	journal	August 2012
Material flow in butt friction stir welds in AA2024-T3 Schmidt, H. N. B.; Dickerson, T. L.; Hattel, J. H. Acta Materialia, Vol. 54, Issue 4 https://doi.org/10.1016/j.actamat.2005.10.052	journal	February 2006
Two-dimensional friction stir welding process model based on fluid mechanics Seidel, T. U.; Reynolds, A. P. Science and Technology of Welding and Joining, Vol. 8, Issue 3 https://doi.org/10.1179/136217103225010952	journal	June 2003
Comparison of a Fluid and a Solid Approach for the Numerical Simulation of Friction Stir Welding with a Non-Cylindrical Pin Bussetta, Philippe; Dialami, Narges; Boman, Romain steel research international, Vol. 85, Issue 6 https://doi.org/10.1002/SRIN.201300182	journal	December 2013
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
R-ALE simulation of heat transfer during friction stir welding of an AA2xxx/AA7xxx joint on a large process window Robe, Hugo; Claudin, Christophe; Bergheau, Jean-Michel International Journal of Mechanical Sciences, Vol. 155 https://doi.org/10.1016/J.IJMECSCI.2019.02.029	journal	May 2019
Numerical simulations of target hole diameters for hypervelocity impacts into elevated and room temperature bumpers Corbett, B. M. International Journal of Impact Engineering, Vol. 33, Issue 1-12 https://doi.org/10.1016/j.ijimpeng.2006.09.086	journal	December 2006
3-Dimensional CFD modelling of flow round a threaded friction stir welding tool profile Colegrove, Paul A.; Shercliff, Hugh R. Journal of Materials Processing Technology, Vol. 169, Issue 2 https://doi.org/10.1016/j.jmatprotec.2005.03.015	journal	November 2005
Finite element analysis of laser shock peening of 2050-T8 aluminum alloy Hfaiedh, Neila; Peyre, Patrice; Song, Hongbin International Journal of Fatigue, Vol. 70 https://doi.org/10.1016/j.ijfatigue.2014.05.015	journal	January 2015
Thermal energy generation and distribution in friction stir welding of aluminum alloys Su, H.; Wu, C. S.; Pittner, A. Energy, Vol. 77 https://doi.org/10.1016/j.energy.2014.09.045	journal	December 2014
A fast and accurate two-stage strategy to evaluate the effect of the pin tool profile on metal flow, torque and forces in friction stir welding Dialami, N.; Cervera, M.; Chiumenti, M. International Journal of Mechanical Sciences, Vol. 122 https://doi.org/10.1016/J.IJMECSCI.2016.12.016	journal	March 2017
Tool-workpiece stick-slip conditions and their effects on torque and heat generation rate in the friction stir welding Wang, Xue; Gao, Yanfei; Liu, Xun Acta Materialia, Vol. 213 https://doi.org/10.1016/j.actamat.2021.116969	journal	July 2021
Material flow visualization in Friction Stir Welding via particle tracing Dialami, N.; Chiumenti, M.; Cervera, M. International Journal of Material Forming, Vol. 8, Issue 2 https://doi.org/10.1007/s12289-013-1157-4	journal	December 2013
Experimental Analysis and Microstructure Modeling of Friction Stir Extrusion of Magnesium Chips Behnagh, Reza Abdi; Shen, Ninggang; Ansari, Mohammad Ali Journal of Manufacturing Science and Engineering, Vol. 138, Issue 4 https://doi.org/10.1115/1.4031281	journal	October 2015
Wear behaviour of steel coatings produced by friction surfacing Pereira, D.; Gandra, J.; Pamies-Teixeira, J. Journal of Materials Processing Technology, Vol. 214, Issue 12 https://doi.org/10.1016/j.jmatprotec.2014.06.003	journal	December 2014
CFD modelling of friction stir welding of thick plate 7449 aluminium alloy Colegrove, P. A.; Shercliff, H. R. Science and Technology of Welding and Joining, Vol. 11, Issue 4 https://doi.org/10.1179/174329306X107700	journal	July 2006
SPH elastic dynamics Gray, J. P.; Monaghan, J. J.; Swift, R. P. Computer Methods in Applied Mechanics and Engineering, Vol. 190, Issue 49-50 https://doi.org/10.1016/S0045-7825(01)00254-7	journal	October 2001
Computational Modeling and Sub-Grid Scale Stabilization of Incompressibility and Convection in the Numerical Simulation of Friction Stir Welding Processes de Saracibar, C. Agelet; Chiumenti, M.; Cervera, M. Archives of Computational Methods in Engineering, Vol. 21, Issue 1 https://doi.org/10.1007/s11831-014-9094-z	journal	February 2014
Detailed thermal and material flow analyses of friction stir forming using a three-dimensional particle based model Fagan, Timothy; Lemiale, Vincent; Nairn, John Journal of Materials Processing Technology, Vol. 231 https://doi.org/10.1016/j.jmatprotec.2016.01.009	journal	May 2016
Smoothed Particle Hydrodynamics (SPH): an Overview and Recent Developments Liu, M. B.; Liu, G. R. Archives of Computational Methods in Engineering, Vol. 17, Issue 1 https://doi.org/10.1007/s11831-010-9040-7	journal	February 2010
3D numerical models using a fluid or a solid formulation of FSW processes with a non-cylindrical pin Bussetta, Philippe; Dialami, Narges; Chiumenti, Michele Advanced Modeling and Simulation in Engineering Sciences, Vol. 2, Issue 1 https://doi.org/10.1186/S40323-015-0048-2	journal	November 2015
Thermomechanical total Lagrangian SPH formulation for solid mechanics in large deformation problems Ba, Kadiata; Gakwaya, Augustin Computer Methods in Applied Mechanics and Engineering, Vol. 342 https://doi.org/10.1016/j.cma.2018.07.038	journal	December 2018
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
Numerical simulation of friction extrusion process Zhang, H.; Li, X.; Deng, X. Journal of Materials Processing Technology, Vol. 253 https://doi.org/10.1016/j.jmatprotec.2017.10.053	journal	March 2018
Computational fluid dynamics simulation of friction stir welding: A comparative study on different frictional boundary conditions Chen, Gaoqiang; Ma, Qingxian; Zhang, Shuai Journal of Materials Science & Technology, Vol. 34, Issue 1 https://doi.org/10.1016/j.jmst.2017.10.015	journal	January 2018
Validation of numerical codes for impact and explosion cratering: Impacts on strengthless and metal targets Pierazzo, E.; Artemieva, N.; Asphaug, E. Meteoritics & Planetary Science, Vol. 43, Issue 12 https://doi.org/10.1111/j.1945-5100.2008.tb00653.x	journal	December 2008
Experimental and numerical studies on the behavior of thin aluminum plates subjected to impact by blunt- and hemispherical-nosed projectiles Gupta, N. K.; Iqbal, M. A.; Sekhon, G. S. International Journal of Impact Engineering, Vol. 32, Issue 12 https://doi.org/10.1016/j.ijimpeng.2005.06.007	journal	December 2006
Steady state thermomechanical modelling of friction stir welding Bastier, A.; Maitournam, M. H.; Dang Van, K. Science and Technology of Welding and Joining, Vol. 11, Issue 3 https://doi.org/10.1179/174329306X102093	journal	May 2006
Strain and texture in friction extrusion of aluminum wire Li, X.; Tang, W.; Reynolds, A. P. Journal of Materials Processing Technology, Vol. 229 https://doi.org/10.1016/j.jmatprotec.2015.09.012	journal	March 2016
A numerical approach to the testing of the fission hypothesis Lucy, L. B. The Astronomical Journal, Vol. 82 https://doi.org/10.1086/112164	journal	December 1977
3D numerical models of FSW processes with non-cylindrical pin Bussetta, P.; Dialami, N.; Chiumenti, M. Advances in Materials and Processing Technologies, Vol. 1, Issue 3-4 https://doi.org/10.1080/2374068X.2015.1121035	journal	October 2015
Investigation of material deformation in multi-pass conventional metal spinning Wang, Lin; Long, Hui Materials & Design, Vol. 32, Issue 5 https://doi.org/10.1016/j.matdes.2010.12.021	journal	May 2011
Numerical modelling of stress fields and fracture around magma chambers Gray, J. P.; Monaghan, J. J. Journal of Volcanology and Geothermal Research, Vol. 135, Issue 3 https://doi.org/10.1016/j.jvolgeores.2004.03.005	journal	July 2004
Thermo-mechanical and metallurgical aspects in friction stir processing of AZ31 Mg alloy—A numerical and experimental investigation Albakri, A. N.; Mansoor, B.; Nassar, H. Journal of Materials Processing Technology, Vol. 213, Issue 2 https://doi.org/10.1016/j.jmatprotec.2012.09.015	journal	February 2013
Solid mechanics-based Eulerian model of friction stir welding Zhang, Z.; Zhang, H. W. The International Journal of Advanced Manufacturing Technology, Vol. 72, Issue 9-12 https://doi.org/10.1007/s00170-014-5789-4	journal	June 2014
Numerical study of friction stir welding plunging phase using smoothed particle hydrodynamics Ansari, Mohammad Ali; Behnagh, Reza Abdi Modelling and Simulation in Materials Science and Engineering, Vol. 27, Issue 5 https://doi.org/10.1088/1361-651X/ab1ca7	journal	May 2019
Smoothed particle hydrodynamics: theory and application to non-spherical stars Gingold, R. A.; Monaghan, J. J. Monthly Notices of the Royal Astronomical Society, Vol. 181, Issue 3 https://doi.org/10.1093/mnras/181.3.375	journal	December 1977
Challenges in Thermo-mechanical Analysis of Friction Stir Welding Processes Dialami, N.; Chiumenti, M.; Cervera, M. Archives of Computational Methods in Engineering, Vol. 24, Issue 1 https://doi.org/10.1007/s11831-015-9163-y	journal	January 2016
Dynamic explicit FE modeling of hot ring rolling process Wang, Min; Yang, He; Sun, Zhi-chao Transactions of Nonferrous Metals Society of China, Vol. 16, Issue 6 https://doi.org/10.1016/S1003-6326(07)60006-5	journal	December 2006
Magnesium alloy ZK60 tubing made by Shear Assisted Processing and Extrusion (ShAPE) Whalen, S.; Overman, N.; Joshi, V. Materials Science and Engineering: A, Vol. 755 https://doi.org/10.1016/j.msea.2019.04.013	journal	May 2019
Strain Rates and Grain Growth in Al 5754 and Al 6061 Friction Stir Spot Welds Gerlich, A.; Yamamoto, M.; North, T. H. Metallurgical and Materials Transactions A, Vol. 38, Issue 6 https://doi.org/10.1007/s11661-007-9155-0	journal	June 2007
A local model for the thermomechanical conditions in friction stir welding Schmidt, H.; Hattel, J. Modelling and Simulation in Materials Science and Engineering, Vol. 13, Issue 1 https://doi.org/10.1088/0965-0393/13/1/006	journal	December 2004
Coupled thermo-mechanical model based comparison of friction stir welding processes of AA2024-T3 in different thicknesses Zhang, Z.; Chen, J. T.; Zhang, Z. W. Journal of Materials Science, Vol. 46, Issue 17 https://doi.org/10.1007/s10853-011-5537-1	journal	September 2011
A numerical model for Wire integrity prediction in Friction Stir Extrusion of magnesium alloys Baffari, Dario; Buffa, Gianluca; Fratini, Livan Journal of Materials Processing Technology, Vol. 247 https://doi.org/10.1016/j.jmatprotec.2017.04.007	journal	September 2017
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. Journal of Manufacturing Processes, Vol. 32 https://doi.org/10.1016/j.jmapro.2018.03.030	journal	April 2018
A meshfree computational framework for the numerical simulation of the solid-state additive manufacturing process, additive friction stir-deposition (AFS-D) Stubblefield, G. G.; Fraser, K.; Phillips, B. J. Materials & Design, Vol. 202 https://doi.org/10.1016/j.matdes.2021.109514	journal	April 2021
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
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
Modeling of Friction Stir Welding (FSW) Process with Smooth Particle Hydrodynamics (SPH) Tartakovsky, Alexandre; Grant, Glenn; Sun, Xin SAE 2006 World Congress & Exhibition, SAE Technical Paper Series https://doi.org/10.4271/2006-01-1394	conference	April 2006
Local–global strategy for the prediction of residual stresses in FSW processes Dialami, N.; Cervera, M.; Chiumenti, M. The International Journal of Advanced Manufacturing Technology, Vol. 88, Issue 9-12 https://doi.org/10.1007/s00170-016-9016-3	journal	June 2016
A study on the variation of forces and temperature in a friction stir welding process: A finite element approach Jain, Rahul; Pal, Surjya K.; Singh, Shiv B. Journal of Manufacturing Processes, Vol. 23 https://doi.org/10.1016/j.jmapro.2016.04.008	journal	August 2016
Numerical investigation of the tool contact condition during friction stir welding of aerospace aluminium alloy Wang, Hua; Colegrove, Paul A.; dos Santos, Jorge F. Computational Materials Science, Vol. 71 https://doi.org/10.1016/j.commatsci.2013.01.021	journal	April 2013

Similar Records

Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method

Journal Article · 2022 · Materials & Design · OSTI ID:1883352

Li, Lei; Reza-E-Rabby, Md; Overman, Nicole R.; +5 more

Meshfree Process Modeling and Experimental Validation of Friction Riveting of Aluminum 5052 to Aluminum 6061

Conference · 2024 · OSTI ID:2406915

Li, Lei; Pole, Mayur; Das, Hrishikesh; +4 more

Processing and mechanical properties - 2016-0032

Conference · 2016 · OSTI ID:22788403

Gaillac, Alexis; Barberis, Pierre

Title: Meshfree simulation and experimental validation of extreme thermomechanical conditions in friction stir extrusion

Citation Formats

References (54)

Similar Records

Related Subjects