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Effects of FSW tool plunge depth on properties of an Al-Mg-Si alloy T-joint: Thermomechanical modeling and experimental evaluation
Memon, Shabbir Fydrych, Dariusz Fernandez, Aintzane C. Aghajani Derazkola, Hamed Derazkola, Hesamoddin A.
Memon, Shabbir
Fydrych, Dariusz
Fernandez, Aintzane C.
Aghajani Derazkola, Hamed
Derazkola, Hesamoddin A.
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2021-08-23
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Friction stir welding,Al-Mg-Si alloy,T-joint configuration,Tool plunge depth,Thermomechanical simulation
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Citation
Memon, S., Fydrych, D., Fernandez, A. C., Derazkola, H. A., & Derazkola, H. A. (2021). Effects of fsw tool plunge depth on properties of an al-mg-si alloy t-joint: Thermomechanical modeling and experimental evaluation. Materials, 14(16) doi:10.3390/ma14164754
Abstract
One of the main challenging issues in friction stir welding (FSW) of stiffened structures is
maximizing skin and flange mixing. Among the various parameters in FSW that can affect the quality
of mixing between skin and flange is tool plunge depth (TPD). In this research, the effects of TPD
during FSW of an Al-Mg-Si alloy T-joint are investigated. The computational fluid dynamics (CFD)
method can help understand TPD effects on FSW of the T-joint structure. For this reason, the CFD
method is employed in the simulation of heat generation, heat distribution, material flow, and defect
formation during welding processes at various TPD. CFD is a powerful method that can simulate
phenomena during the mixing of flange and skin that are hard to assess experimentally. For the
evaluation of FSW joints, macrostructure visualization is carried out. Simulation results showed that
at higher TPD, more frictional heat is generated and causes the formation of a bigger stir zone. The
temperature distribution is antisymmetric to the welding line, and the concentration of heat on the
advancing side (AS) is more than the retreating side (RS). Simulation results from viscosity changes
and material velocity study on the stir zone indicated that the possibility of the formation of a tunnel
defect on the skin–flange interface at the RS is very high. Material flow and defect formation are very
sensitive to TPD. Low TPD creates internal defects with incomplete mixing of skin and flange, and
high TPD forms surface flash. Higher TPD increases frictional heat and axial force that diminish the
mixing of skin and flange in this joint. The optimum TPD was selected due to the best materials flow
and final mechanical properties of joints.
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Copyright: © 2021 by the authors.
Licensee MDPI, Basel, Switzerland.
This article is an open access article
distributed under the terms and
conditions of the Creative Commons
Attribution (CC BY) license (https://
creativecommons.org/licenses/by/
4.0/).
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MDPI
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Materials
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1996-1944