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Heat Flow analysis of Friction Stir welding by 3-D Finite Element Method

Conference Paper · February 2008

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Pankaj Biswas
Indian Institute of Technology Guwahati
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SUPPLEMENT TO THE WELDING JOURNAL, JULY 2011


Sponsored by the American Welding Society and the Welding Research Council

Effect of Tool Geometries on Thermal


History of FSW of AA1100
The peak temperatures measured, which have major influence on the
overall welding process, were found to be in very good
agreement with the calculated values

BY P. BISWAS AND N. R. MANDAL

In FSW, there are two sources of heat


ABSTRACT generation. One through friction and the
other due to plastic deformation at the
In the present work, three-dimensional finite element (FE) transient thermal analy- tool-workpiece interface and at the ther-
sis of friction stir welding (FSW) was presented for different tool geometries and dif- momechanically-affected zone (TMAZ)
ferent process parameters. The source of heat generation was assumed to be pure (Refs. 7–9). The tool-workpiece interface
friction between the tool and workpiece interface. Thermal history of FSW of 6-mm-

WELDING RESEARCH
can be further subdivided into shoulder-
thick AA1100 plates for different tool geometries was calculated. The estimated ther- workpiece and tool pin-workpiece inter-
mal profiles compared well with those of the experimental results, thus validating the face. In most models (Refs. 10–16), heat
various assumptions made in the work. It was observed that in FSW of AA1100 with generated from the tool pin was neglected.
SS310 tool, friction is the major contributor to heat generation. Tool geometry with Ulysse (Ref. 17) presented a 3D finite
concave shoulder and conical pin was found to be preferable for FSW of AA 1100. It element model for determining the tem-
is preferable to keep the tool pin diameter as small as possible to avoid occurrence of perature profile using a commercial FEM
a wormhole defect. Tool plunging force reduced significantly with an increase in tool (finite element method) code FIDAP. The
rotational speed; however, the increase in heat generation was marginal. heat generation rate was expressed as the
product of the effective flow stress and the
effective strain rate. Reasonable agree-
Introduction the pin can be quite complex (Ref. 3). De-
ment between the predicted and the meas-
sign of tools based on quantitative under-
ured temperature was reported.
standing of material flow is just beginning
Friction stir welding (FSW) is a solid- Chen and Kovacevic (Ref. 18) devel-
(Ref. 2). Colegrove and Shercliff (Refs. 4,
state joining technique. The welds are cre- oped a 3D finite element model to study the
5) suggested that Trivex™ tools with their
ated by the combined action of frictional thermal history and thermomechanical phe-
convex surfaces avoid sticking to the ma-
heating and mechanical deformation due nomena in butt-joint welding of aluminum
terial, thus reducing the shear force at the
to a rotating tool. The majority of the heat Alloy 6061-T6 using a commercial FEM
tool-metal interface, leading to reduction
generated from the friction, i.e., about code ANSYS. Their model incorporated
in traverse force. However, at the same
95%, is transferred into the workpiece and the mechanical reaction between the tool
time, they observed that the heat gener-
only 5% flows into the tool (Ref. 1). The and the weld material. X-ray diffraction
ated, as well as the power requirement, re-
maximum temperature created by the technique was used to measure the residual
mained unchanged by different tool
FSW process ranges from 80 to 90% of the stress in the welded plate.
designs. During FSW, the material under-
melting temperature of the material being A few models did consider the effect of
goes intense plastic deformation at ele-
welded. tool pin on heat generation (Refs. 19–21).
vated temperature, resulting in generation
The localized heating softens the ma- For instance, in Colegrove et al. (Ref. 19)
of fine and equiaxed recrystallized grains
terial around the pin. Tool rotation and 20% of the total heat was attributed to the
(Ref. 6). The fine microstructure in fric-
translation leads to movement of material pin, yet, they concluded that the addition
tion stir welds results in improved me-
from the front of the pin to the back of the of heat due to the pin had little effect on
chanical properties.
pin. As a result of this process, a joint is the thermal profile produced from the
produced in the solid state. Plastic flow in modeling. However, tool pin geometry was
FSW is a complex phenomenon due to the not given in the report. The relative con-
interaction of the variation of strain rates tributions of the heat generated from
KEYWORDS
and flow stress leading to variation in vis- these two sources remained unknown.
cosity, which affects the flow (Ref. 2). Be- Nandan et al. (Refs. 22, 23) combined
Finite Element Analysis
cause of various geometrical features of viscoplastic flow with heat transfer to
Transient Thermal Analysis
the tool, the material movement around study the three-dimensional FSW process
Friction Stir Welding
in 6061 aluminum alloy. They (Ref. 24)
Temperature-Dependent
P. BISWAS (panu012@yahoo.co.in) is research further expanded the study to mild steel.
Material Properties
associate and N. R. MANDAL (nrm@naval Although they claimed that the computed
.iitkgp.ernet.in) is professor, Department of Tool Geometries
temperatures were in good agreement
Ocean Engineering and Naval Architecture, In- with the corresponding experimentally de-
dian Institute of Technology, Kharagpur, India. termined values, only temperatures at one

WELDING JOURNAL 129-s


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(Ref. 30) toward the total heat generation


required for welding. Q1 and Q2 are the
components of the respective heat gener-
ated from the tool shoulder and tool pin
side interfaces, as shown in Fig. 1. There-
fore, the total heat generated is given by
Qtotal = Q1 + Q2 .

Tool Shoulder - Workpiece Interface

The expressions were derived consid-


ering a concave shoulder surface. The pur-
pose of this geometric feature is to act as
an escape volume as the tool pin is
plunged into the plate during the welding
operation.
The concave shoulder surface is repre-
sented by its vertical and horizontal pro-
jected surfaces as AV and AH, respectively.
Fig. 1 — Segmental areas and heat generation on Fig. 2 — Force acting on FSW tool pin due to welding. Therefore, for an elemental segment
different parts of the FSW tool.
dAV = r dθ dz
now dz = tan α dr ,
remote point from the tool were reported
therefore, dAV = r dθ tan α dr
(Ref. 24).
dQ p = δω rτ y dA
WELDING RESEARCH

The works of the above investigators (2) and dA H = r dθ dr .


indicate that the heat generation and the
resulting thermal history in a FSW process Therefore, total heat due to friction and
are greatly influenced by tool rotational plastic deformation is given by The forces acting on the tool shoulder
speed and to a much lesser extent by the can be written as
tool traverse speed. Not much information
on the effect of tool geometry, including dQ = dQ f + dQ p dFs = μ p ( dAH + dAV )
that of tool pin on thermal profile, was re- = μ p r dθ dr (1 + tan α )
ported in the literature. The present study = ω rdA ( μ p − δμ p ) + δτ y (7)
therefore focused primarily on the effect
of variation of tool geometry on thermal Let τ contact = ⎡⎣( μ p − δμ p ) + δτ y ⎤⎦ From Equation 7 one can observe that the
(3) concave shoulder surface actually con-
profile. Extensive experiments were car-
ried out to test the simulation results. tributes to increased frictional area by a
Therefore, dQ = ω rdAτ contact factor of tan α.
(4)
Therefore, combining Equations 6 and
Heat Generation 7, the heat generation from the elemental
There is no straightforward mechanism shoulder surface is given by
In FSW, heat is generated due to fric- to estimate the extent of slip. At the same
tion and plastic deformation at the tool- time, with the increase in temperature, the dQS = ω r dFS
workpiece interface and at the TMAZ. yield strength of the workpiece material
The heat generation at the contact sur- decreases, resulting in reduction in heat = ω r 2 μ p dθ dr (1 + tan α ) (8)
faces due to friction is the product of fric- generation from plastic deformation. In
tional force and the tangential speed of such a situation, it was felt more logical to The heat generated through friction of the
the tool with respect to the workpiece. The consider pure friction and neglect the heat tool shoulder with the plate surface is ob-
heat generated per unit area due to plastic generation due to plastic deformation. In tained by integrating Equation 8 from the
deformation at the tool-workpiece inter- the case of pure friction δ = 0. Therefore, pin root radius to the outer radius of the
face is the product of shear stress and the Equation 3 reduces to shoulder surface.
velocity of the workpiece material sticking
τ contact = μ p (5) 2 π RS
to the tool as it traverses. This velocity is
Q1 = ∫ ∫ ωμ pr (1 + tan α ) dr dθ
2
actually the tangential speed of the tool.
The heat generation due to friction on Therefore, from Equations 4 and 5, the 0 Rp
an elemental area dA at the tool-work- expression for heat generation on an ele-
piece interface, considering high rota-
tional speed compared to traverse speed
mental surface area dA at the tool-work-
piece interface is given by
=
2
3
( )
πμ pω RS3 − Rp3 (1 + tan α )
(9)
of the FSW tool, is given by
dQ = ω r μ p dA
Tool Pin-Workpiece Interface
i.e., dQ = ω r dF
dQ f = (1 − δ ) ω r μ pdA (1)
where dF = μ p dA (6) Heat generated from the cylindrical
The three distinct tool-workpiece in- tool pin side surface is denoted by Q2. As
The heat generated due to plastic shear terface surfaces are tool shoulder, tool pin the FSW tool traverses along the joint, the
deformation leading to workpiece mate- side, and tool pin tip. However, the con- forward half of the tool pin experiences a
rial sticking to the tool is given by tribution of tool tip surface is negligible reaction force F as shown in Fig. 2. It is the

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Fig. 3 — Details of tool geometry with cylindrical tool pin. Fig. 4 — Details of tool geometry with conical tool pin.

WELDING RESEARCH
Fig. 5 — Peak temperature distribution along plate breadth perpendicular to Fig. 6 — Peak temperature distribution along plate breadth perpendicular to
the weld interface using cylindrical pin. the weld interface using conical pin.

product of the projected area of the tool Q2 = ω Rp FV to be 1782 J/s (i.e., 89% of total heat
pin and the yield stress of the aluminum (12) input) and 219 J/s (i.e., 11% of total heat
alloy at the prevailing temperature of pin- input), respectively. The percentage of
plate interface as given in Equation 10. Therefore, the total heat generation con- heat generation obtained from the above
The temperature at the pin-plate interface sidering pure friction of tool shoulder and formulation matched well with that of
was taken as about 80% of the melting pin side surface will be given by published results (Ref. 30).
temperature of the plate material, i.e. , Qtotal = Q1 + Q2
530°C. Three-Dimensional Finite
2
(
= πμ pω RS3 − RP3 ) Element Model
( ) ( )
∴ F = hp × d p × σ y 3
530° C (10) (1+tanα ) + ω RP Fv (13)
A three-dimensional FE transient ther-
mal model was developed to determine
Therefore, the frictional force experienced In case of a flat shoulder, the heat gener-
the thermal history on the workpiece
by the tool pin side vertical surface will be ation expression simplifies to
based on the Q1 and Q2 given by Equa-
given as
FV = ( μ )530°C × F
Qtotal =
2
3
(
π μ pω RS3 − RP3 ) tions 9 and 12, respectively. The following
assumptions were made in the analysis:
(11) 1) All the thermal properties of
+ ω RP Fv (14) AA1100 were considered as a function of
Hence, the heat generated due to friction temperature.
of the tool pin side surface will be Using the parameters given in Table 1, the 2) Linear Newtonian convection cool-
calculated values of Q1 and Q2 were found ing was considered on all the surfaces.

Table 1 — Typical FSW Parameters

Thickness of Tool Pin Shoulder Rotational Traverse Speed Average Plunging


Plates (mm) Diameter (mm) Diameter (mm) Speed (rpm) (mm/min) Force on FSW Tool
during Welding (N)
6.0 6.0 25.0 1400 112 5090

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Fig. 7 — Variation of peak temperature distribution with tool rotational Fig. 8 — Experimental setup of FSW process.
speed.

3) 95% of the heat was transferred to Initial Condition done by the friction force only.
the workpiece. The distribution of heat flux (Ref. 26)
A specified initial temperature for the over the plate surface due to the tool
The governing differential equation is
entire plate, shoulder was given as
WELDING RESEARCH

∂ ⎡ ∂T ⎤ ∂ ⎡ ∂T ⎤
K + K T = T∞ for t = 0 3Q1r
∂x ⎢⎣ ∂x ⎥⎦ ∂y ⎢⎣ ∂y ⎥⎦ q (r ) =
(16)
for r ≤ r0
2π RS3 (17)
∂ ⎡ ∂T ⎤ ∂T
+ K =ρC First Boundary Condition
⎢ ⎥
∂z ⎣ ∂z ⎦ ∂t
(15) The distribution of heat flux over the pin-
A specific heat flow acting over weld sur-
The boundary conditions below were ap- plate interface due to tool pin side surface
face for t > 0 representing the FSW heating
plied in the present FE model. was given as
source qn = –qsup. The quantity qsup is the
heat flux supplied to the plate due to fric-
tion at the tool-plate interface. qn is the nor- Q2
qp =
mal component of heat flux vector. Here
qsup was given by Equation 17.
( A ) ps (18)
Table 2 — Temperature-Dependent Properties
of Aluminum Alloy
Second Boundary Condition Where (A)ps is the area of the tool pin side
Temperature Thermal Heat surface.
°C Conductivity Capacity qconv represents the heat loss due to
W/m°C J/Kg°C convection from the plate surface at tem- Material Properties
perature T. Considering hf as convection
37.8 162 945 coefficient, the heat loss qconv is given by
93.3 177 978 The temperature-dependent thermal
qconv = hf (T – T∞). Considering heat loss properties (Ref. 27) of the aluminum alloy
148.9 184 1004
due to convection over the top and bottom used in this analysis are given in Table 2.
204.4 192 1028
260 201 1052
surface (Newton’s law of cooling) Constant convection coefficient, 30
315.6 207 1078 qn = qconv or –k ∂T/∂n = hf (T – T∞) for W/m2°C was used (Ref. 28) in the analysis.
371.1 217 1104 t > 0. It should be noted that heat flux qsup The temperature-dependent friction coef-
426.7 223 1133 and convection loss qconv do not occur ficient of aluminum and steel combination
over the same boundary segment at the (Refs. 26, 27) is given in Table 3. The melt-
same time. Heat flow into the boundary is ing temperature of AA1100 was taken as
taken as positive. 660°C.
Table 3 — Temperature-Dependent Friction
Coefficient of Aluminum and Steel Heat Source Model
Combination FE Results and Discussion

Temperature Friction The heat source modeling was done Transient thermal analysis of FSW of
(°C) Coefficient, μ based on the following assumptions: AA1100 was carried out considering two
1) The heat input is linearly propor- different sets of FSW tools having cylin-
22 0.11 tional to the distance from the center of drical- and conical-shaped tool pins as
160 0.11 the tool. shown in Figs. 3 and 4, respectively. Brick
200 0.26 2) The plunging force applied to the elements with fine meshing in the weld
400 0.35 plate surface by the tool creates a uniform zone were considered.
580 0.47 pressure over the shoulder surface. The vertical tool plunging force was
3) The heat is generated from the work measured using a load pad. It was ob-

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Fig. 9 — Numerical and experimental temperature distribution at 5 and Fig.10 — Numerical and experimental temperature distribution for
20 mm away from the weld center. welding with conical tool pin.

served that the average plunging force re- was only about 13%. It is important to Experimental Details
quired for cylindrical and conical tool pin note that although heat generation de-
varied with tool rotational speed. The pends on tool rotational speed, its effect is Extensive experiments with excellent re-
measured values of plunging force for rather marginal. peatability were carried out to test and val-

WELDING RESEARCH
varying tool rotational speed are given in
Table 4.
The peak temperatures obtained from
Table 4 — Vertical Plunging Force at Varying Tool Rotational Speeds
the results of thermal analysis of FSW of
AA1100 considering traverse speed of 112 Thickness of Rotational Traverse Average Plunging
mm/min and tool rev/min of 1400 for dif- Plates Speed Speed Force on FSW Tool
ferent tool geometries are given in Table (mm) (rpm) (mm/min) during Welding (N)
5. It can be observed that tools having a
concave shoulder led to lesser tempera- 6.0 1000 112 6450
ture rise. At the same time, conical tool 6.0 1400 112 5090
pins exhibited somewhat lesser peak tem- 6.0 2000 112 3800
perature compared to that of a cylindrical
pin having a pin diameter the same as the
base diameter of conical pins.
The variations of calculated peak tem- Table 5 — Peak Temperatures for Different Tool Geometries
perature distributions for two sets of three
different tool geometries with cylindrical Sl. Tool Type Peak % of Melting
and conical tool pins at traverse speed of No. Temperature Temperature
112 mm/min and 1400 rev/min are shown (°C)
in Figs. 5 and 6, respectively.
From Fig. 5 one can observe that with 1 1 Flat shoulder, pin dia. 5 mm 490 74
mm increase in pin diameter peak tem- 2 Flat shoulder, pin dia. 6 mm 540 81.8
3 Cylindrical Flat shoulder, pin dia. 8 mm 598 90.6
perature increased by about 10%. How-
4 Pin Concave shoulder, pin dia. 5 mm 462 70
ever, with the same pin diameter but with 5 Concave shoulder, pin dia. 6 mm 515 78.1
a concave shoulder surface there was 6 Concave shoulder, pin dia. 8 mm 577 87.4
about 4.6% reduction in the peak temper-
ature compared to that of flat shoulder 7 Flat shoulder, pin base dia. 5 mm, 479 72.58
surface. tip dia. 2.5 mm
As expected, welding with the tool pin 8 Flat shoulder, pin base dia. 6 mm, 528 80
having a higher base diameter led to tip dia. 3 mm
higher temperature. Also, a reduction in 9 Flat shoulder, pin base dia. 8 mm, 571 86.5
temperature was observed in the case of tip dia. 3 mm
the tool with concave shoulder. Conical
Figure 7 shows the variation of peak Pin
temperature distribution along plate 10 Concave shoulder, pin base dia. 457 70
breadth perpendicular to the weld inter- 5 mm, tip dia. 2.5 mm
face for varying tool rotational speeds for 11 Concave shoulder, pin base 491 74.4
dia. 6 mm, tip dia. 3 mm
a tool having a 5-mm-diameter cylindri-
12 Concave shoulder, pin base 554 84
cal pin with flat shoulder. dia. 8 mm, tip dia. 4 mm
Here one can observe that with 100%
increase in tool rev/min, i.e., from 1000 to Tool traverse speed = 112 mm/min, Tool rpm = 1400
2000, the increase in peak temperature

WELDING JOURNAL 133-s


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idate the numerical model for calculating the peak temperatures measured, which Acknowledgments
the thermal history of FSW of AA1100. have major influence on the overall weld-
A vertical milling machine with only 7.5 ing process, were found to be in very good The authors sincerely acknowledge the
- hp motor capacity was used to carry out agreement with the calculated ones. A funding support from Naval Research
the FSW experiments. The tools were variation of about 2.4 to 3.3% from the Board to carry out the research, and also
mounted in the vertical arbor using suitable measured data was noted. Hence, it points the generous help extended by Garden
collates. The edges of the test pieces were to the fact that in FSW of AA1100 with a Reach Shipbuilders and Engineers Ltd.,
machined to obtain a neat square butt. They SS310 tool, friction is the major contribu- Kolkata, by providing AA1100 to carry out
were clamped to the horizontal bed with tor to heat generation. the experiments.
zero root opening. The butt line was aligned It was observed that the tendency of a
with the centerline of the FSW tool. The wormhole defect to occur toward the bot-
References
clamping of the test pieces was done such tom of the weld increased when the diam-
that the movement of the plates was totally eter of the tool pin increased in the case
1. Chao, Y. J., Qi, X., and Tang, W. 2003.
restricted under both plunging and transla- of cylindrical tools and increasing base di- Heat transfer in friction stir welding — Experi-
tional forces of the FSW tools. The tool ameter with conical tool pins, irrespective mental and numerical studies, Transaction of the
rev/min and translational speed of the bed of tool rotational or traverse speed. A ASME, pp. 125, 138–145.
were set prior to each run of welding. After higher diameter tool pin implies a higher 2. Nandan, R., DebRoy, T., and Bhadeshia,
plunging the rotating tool at the plate butt volume of material displacement, and H. K. D. H. 2008. Recent advances in friction
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SS310.
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tion during welding, thermocouples were The thermal history obtained through 2004. Development of Trivex friction stir weld-
WELDING RESEARCH

used 5 and 20 mm away from the weld in- the model developed in the present study ing tool part 1 — two-dimensional flow model-
compared fairly well with the experimen- ling and experimental validation. Science and
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18. Chen, C. M., and Kovacevic, R. 2003. Fi- and thermo-mechanical modeling of friction stir p = tool plunging pressure applied on the
nite element modeling of friction stir welding welding of aluminum alloy 6061-T6. Journal of elemental area dA
— thermal and thermo-mechanical analysis. Materials Processing & Manufacturing Science 7:
Machine Tools & Manufacture 43: 1319–1326. 215–233. r = length along tool radius
19. Colegrove, P. A., Painter, M., Graham, D., 27. Wong, J. C. 2008. The Correspondence
and Miller, T. 2002. 3 Dimensional flow and ther- between Experimental Data and Computer Sim- AH = horizontal projected surfaces area
mal modeling of the friction stir welding process. ulation of Friction Stir Welding (FSW). Master AV = vertical projected surfaces area
2nd International Symposium on Friction Stir Weld- of Science in Mechanical Engineering, Depart-
ing, Gothenburg, Sweden, pp. 26–28. ment of Mechanical and Aerospace Engineering, Q = heat input to the workpiece
20. Dong, P., Lu, F., Hong, J. K., and Cao, Z. Morgantown, W. V.
2001. Coupled thermomechanical analysis of 28. Chao, Y. J., Qi, X., and Tang, W. 2003. Q1= heat generated under the tool
friction stir welding process using simplified Heat transfer in friction stir welding-experimen- shoulder
models. Science and Technology of Welding and tal and numerical studies. Transactions of the
Joining 6(5): 281–287. ASME, 125, 138–145. Q2 = heat generated at the tool pin side
21. Shi, Q. Y., Dickerson, T., and Shercliff, 29. Metals Handbook. 1979. Ninth edition,
H. R. 2003. Thermo-mechanical FE modeling Vol. 2, ASM International, p. 104. Q3 = heat generated at the tool pin tip
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WELDING RESEARCH
loads. 4th International Symposium on Friction and Z. Chen, eds., Woodhead Publishing Ltd.,
Stir Welding, Park City, Utah. pp. 282 and 309. RP = pin root radius
22. Nandan, R., Roy, G. G., and Deb- Roy, T.
2006. Numerical simulation of three-dimensional RS = outer radius of shoulder surface
heat transfer and plastic flow during friction stir Nomenclature
T∞ = ambient temperature
welding. Metallurgical and Materials Transaction
A 37(4): 1247–59. α = shoulder concavity angle
23. Nandan, R., Roy, G. G., Lienert, T., and
DebRoy, T. 2006. Numerical modelling of 3D δ = extent of slip

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