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Probing the Mechanism of Friction Stir Welding with ALE Based Finite Element Simulations and Its Application to Strength Prediction of Welded Aluminum

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Abstract

In this study, a simulation-based examination on the deformation mechanism in the friction stir welding (FSW) process is conducted, which may not be efficiently feasible by experiment due to severe deformation and rotation of material flow near a tool pin. To overcome the severity of distortion of plastically deforming finite element meshes in the Lagrange formulation, and an over-simplified elastic-plasticity constitutive law and contact assumption in the Eulerian formulation, the arbitrary Lagrangian–Eulerian (ALE) formulation is employed for the finite element simulations. Superior accuracy in predicting the temperature profiles and distributions of the friction stir welded aluminum alloy workpiece could be obtained compared to the results of Eulerian based simulations. In particular, the ALE based simulations could predict the sharper gradient of temperature decrease as the distance from the welding zone increases, while the Eulerian based model gives more uniform profiles. The second objective of the study is to investigate the coupling of simulation-based temperature histories into the strength prediction model, which is formulated on the basis of precipitation kinetics and precipitate-dislocation interaction. The calculated yield strength distribution is also in better agreement with experiment than that by the Eulerian based model. Finally, the mechanism of the FSW process is studied by thoroughly examining the frictional and material flow behavior of the aluminum alloy in the welded zone. It is suggested that the initially high rate of temperature increase is attributed to frictional heat due to slipping of material on the tool surface, and the subsequent saturated temperature is the result of sequential repetitive activations of the sticking and slipping modes of the softened material. The sticking mode is the main source of plastically dissipated heat by the large plastic deformation around the rotating tool pin. The present integrated finite element simulation and microstructure-based strength prediction model may provide an efficient tool for the design of the FSW process.

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Notes

  1. In the modeling of heat generation by plastic deformation, the Eulerian based simulation with FLUENT software by Kim et al. [15] used a conversion factor 1.0, but the interfacial friction heat was neglected.

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Acknowledgements

MGL and DJM appreciate the support of LG Chem. They also appreciate the partial supports by the NRF of Korea (No. 2019R1A5A6099595). DJM thanks to Mr. Chanyang Kim who helped the ALE simulations and material identification which were partially supported by KIAT (No. P0002019). The constitutive modeling for the high temperature mechanical properties are acknowledged from the work supported by the Technology Innovation Program (Grant No. 10063488) funded by the Ministry of Trade, Industry and Energy (MOTIE).

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Authors and Affiliations

  1. Department of Material Science and Engineering and RIAM, Seoul National University, Seoul, 08826, Republic of Korea

    Dongjoon Myung & Myoung-Gyu Lee

  2. Converged Process R&D Group, Korea Institute of Industrial Technology, Incheon, 21999, Republic of Korea

    Wooram Noh

  3. School of Mechanical Engineering, Pusan National University, Busan, 46241, Republic of Korea

    Ji-Hoon Kim

  4. Pack Element Technology Development, LG Chem. R&D Center Campus Gwacheon, Gwacheon, 13818, Republic of Korea

    Jinhak Kong

  5. Department of Mechanical Engineering, University of Ulsan, Ulsan, 44610, Republic of Korea

    Sung-Tae Hong

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  1. Dongjoon Myung
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  2. Wooram Noh
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Correspondence to Myoung-Gyu Lee.

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Myung, D., Noh, W., Kim, JH. et al. Probing the Mechanism of Friction Stir Welding with ALE Based Finite Element Simulations and Its Application to Strength Prediction of Welded Aluminum. Met. Mater. Int. 27, 650–666 (2021). https://doi.org/10.1007/s12540-020-00901-8

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