Process - Property Correlation of Friction Stir Welding of Marine Grade Aluminium Alloy 5083 Using Finite Element Analysis
2021
In this article, a 3D finite element based thermo-mechanical model for friction stir
welding (FSW) of a marine-grade aluminium alloy 5083 is proposed. The model demonstrates
the thermal evaluation and the distribution of residual stresses and strains under
the variation of process variables. The temperature profile of the weld joint during
the FSW process and the mechanical properties of the joints are also experimentally
evaluated. The necessary calibration of the model for the correct implementation of
the thermal loading, mechanical loading, and boundary conditions was performed using
the experimental results. The model simulation and experimental results are analyses
in view of the process-property correlation study. The residual stress was evaluated
along, and across the weld, centreline referred as longitudinal and transverse residual
stresses, respectively. The magnitude of longitudinal residual stress is noted 60-80%
higher than that of the transverse direction. The longitudinal residual stress generated
a tensile oval shaped stress region around the tool shoulder confined to a maximum
distance of about 25mm from the axis of the tool along the weld line. It encompasses
the weld-nugget to thermo-mechanically affected zone (TMAZ), while the parent metal
region is mostly experiences the compressive residual stresses. However, the transverse
residual stress region appears like wing shaped region spread out in both the advancing
and retreating side of the weld and occupying approximately double the area as compared
to the longitudinal residual stresses. Overall, the study revealed a corelation between
the FSW process variables such as welding speed and the tool rotational speed with
the residual stress and the mechanical properties of the joint.
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