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Friction stir welding of AA2024-T3: development of numerical simulation considering thermal history and heat generation

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Abstract

This paper proposes a finite element model implemented in ANSYS using Lagrangian formulation to assess heat generation and friction dynamics of a friction stir welding process on AA2024-T3 aluminum plates. For that aim, the model is enriched by estimating a temperature-dependent friction coefficient using theoretical relationships, and by considering a temperature-dependent multilinear isotropic hardening equation as a plasticity model representing the material. Both quantitative determinations are confirmed through experimental data collected on the real material. Finally, the contact conditions are modeled using the modified Coulomb criterion. The results of the model are in agreement with actual results observed on experimental applications. The study proves that the rotational speed of the tool is the most determinant factor in the results. As it rises, the friction-generated heat flow is higher. This study shows that the compressive stress-strain data in strain rate of 10s−1 is a good approximation of the plasticity behavior of aluminum alloy during the friction stir welding.

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Funding

Financial support for this study was provided by the Iran Ministry of Science Research and Technology, which is greatly appreciated.

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Authors and Affiliations

  1. Mechanical Engineering Department, University of Tabriz, 29 Bahman Blvd, Tabriz, 5166616471, Iran

    Cyrus Amini, Soran Hasanifard & Mohammad Zehsaz

  2. Escola d’Enginyeria de Barcelona Est, Mechanical Engineering Department, Universitat Politècnica de Catalunya, Carrer d’Eduard Maristany, 10-12, 08019, Barcelona, Spain

    Ramón Jerez-Mesa & J. Antonio Travieso-Rodriguez

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  1. Cyrus Amini
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  2. Soran Hasanifard
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Contributions

Conceptualization, S.H., M.Z., J.A.T.-R., and R.J.-M.; Methodology, R.J., M.Z., C.A. and J.A.T-R; Software, S.H. and C.A.; Validation, C.A., J.A.T.-R., and R.J.-M.; Formal Analysis, C.A., J.A.T.-R., and R.J.-M.; Investigation, R.J.-M., J.A.T.-R., and C.A.; Resources, J.A.T.-R., and R.J.-M.; Data Curation, S.H., M.Z., and C.A.; Writing-Original Draft Preparation, C.A.; Writing-Review & Editing, J.A.T.-R., and R.J.-M.; Visualization, C.A., S.H., and M.Z.; Supervision, S.H., M.Z., J.A.T.-R., and R.J.-M.; Project Administration, J.A.T.-R., Funding Acquisition, J.A.T.-R., R.J.-M.

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Correspondence to Cyrus Amini.

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Amini, C., Hasanifard, S., Zehsaz, M. et al. Friction stir welding of AA2024-T3: development of numerical simulation considering thermal history and heat generation. Int J Adv Manuf Technol 117, 2481–2500 (2021). https://doi.org/10.1007/s00170-021-07184-2

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