使用 CEL 方法分析三楔销几何形状对 FSW 中缺陷形成和材料流动的影响

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY Journal of Advanced Joining Processes Pub Date : 2024-10-10 DOI:10.1016/j.jajp.2024.100259
Mostafa Akbari , Parviz Asadi
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引用次数: 0

摘要

搅拌摩擦焊接(FSW)中复杂的工具销钉设计需要考虑材料流动和缺陷形成。本研究采用数值方法研究了三楔形工具的几何参数对温度、应变、空洞形成和材料混合的影响。数值模型采用欧拉-拉格朗日(CEL)耦合公式,成功预测了搅拌摩擦焊(FSW)过程中的空洞形成和材料混合。在材料流动方面,考虑了四种工具销钉设计,包括一个圆柱销钉和三个三楞销钉,其楞半径分别为 1 毫米、1.5 毫米和 2 毫米。研究结果表明,搅拌区分为肩部驱动区和销轴驱动区,每个区都表现出不同的材料流动模式。在肩部驱动区,材料主要流向前进的一侧,而在销钉驱动区,材料则流向后退的一侧。FSW 针工具上的凹槽增加了搅拌区的扫描速度、应变和材料运动。然而,半径较大的凹槽会扫过更多的材料,因此需要更多的软化材料来促进运动。因此,为了形成无缺陷的接缝,需要提高工具的旋转速度,这可能会对工具的使用寿命和接缝的机械性能产生不利影响。在增强材料流动和实现无缺陷焊接方面,半径较小的凹槽(1 毫米)的效果明显优于半径较大的凹槽(1.5 毫米或 2 毫米)。
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Effects of triflute pin geometry on defect formation and material flow in FSW using CEL approach
Complicated tool pin designs in Friction Stir Welding (FSW) need to be considered in terms of material flow and defect formation. This study investigates the effects of the triflute tool's geometrical parameters on temperature, strain, void formation, and material mixing using a numerical method. The numerical model employs a coupled Eulerian-Lagrangian (CEL) formulation and successfully predicts void formation and material mixing during friction stir welding (FSW). Four tool pin designs are considered for material flow, including one cylindrical pin and three triflute pins with flute radii of 1 mm, 1.5 mm, and 2 mm. The findings indicate that the stir zone is divided into shoulder-driven and pin-driven zones, each exhibiting distinct material flow patterns. In the shoulder-driven zone, material flow toward the advancing side is dominant, while in the pin-driven zone, it flows toward the retreating side. Flutes on the FSW pin tool increase the sweeping rate, strain, and material movement in the stir zone. However, flutes with a larger radius sweep a greater amount of material and thus require more softened material to facilitate movement. Therefore, for defect-free joint formation, a higher rotational speed of the tool will be required, which may adversely affect tool lifespan and joint mechanical properties. The effectiveness of flutes with a smaller radius of 1 mm is significantly greater than that of those with a larger radius (1.5 or 2 mm) in enhancing material flow and achieving defect-free welding.
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来源期刊
CiteScore
7.10
自引率
9.80%
发文量
58
审稿时长
44 days
期刊最新文献
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