Friction Stir Welding of an Aluminum
Friction Stir Welding of an Aluminum
Plate
COMSOL
Background
Manufacturers use a modern welding method called friction stir welding to join aluminum
plates
A rotating tool moves along the weld joint and softens aluminum by generating frictional
heat. The rotation then stirs the softened aluminum so that the two plates are joined
This method allows dissimilar materials and plastics to be welded together
The result is a pore-free weld joint without residual stresses due to shrinkage
Heat transfer between the rotating tool and the plate during welding is considered in this
model
Model Definition
A symmetry is introduced to reduce the
computational cost
Instead of modeling the tool as a
moving heat source, a moving
coordinate system fixed to the tool axis
is used
Two infinite element domains , before
and after the welding zone, are used to
model an infinitely long plate
The rotating tool is divided into two
parts: a pin with an inner contact, and a
shoulder with a contact surface on the
plate. The shoulder itself is not
represented
Model geometry
Model Definition
Heat fluxes from friction with the
rotating tool are taken into account on
both contact surfaces. They account for
the rotating speed and the normal force
The heat fluxes from friction are set to
0 if the temperature exceeds the
melting temperature
Surface-to-ambient radiation as well as
convection are considered on the plate
The right side of the infinite plate,
which corresponds to the supply side, is
set to ambient temperature
Model boundary conditions
Results
In this configuration the maximum
temperature is 935 K which is
slightly higher than the melting
temperature of aluminum (T=933 K)
There is a thin film of aluminum that
melts at the very surface in contact
with the shoulder and the pin
Cold material arrives on the welding
tool as the plate moves
The high temperatures created by
the friction with the tool are then
transported
Isothermal contours in the domain - In blue, the area where the
temperature exceeds 933 K
Manufacturers utilize friction stir welding to join aluminum plates, creating pore-free weld joints with minimal residual stresses. This method allows for welding dissimilar materials and plastics together, offering benefits such as strong thermal properties and enhanced structural integrity. Through a detailed model definition and consideration of heat transfer mechanisms during welding, the process is optimized for efficiency and quality.
Download Presentation
Please find below an Image/Link to download the presentation.
The content on the website is provided AS IS for your information and personal use only. It may not be sold, licensed, or shared on other websites without obtaining consent from the author.If you encounter any issues during the download, it is possible that the publisher has removed the file from their server.
You are allowed to download the files provided on this website for personal or commercial use, subject to the condition that they are used lawfully. All files are the property of their respective owners.
The content on the website is provided AS IS for your information and personal use only. It may not be sold, licensed, or shared on other websites without obtaining consent from the author.
E N D
Presentation Transcript
Friction Stir Welding of an Aluminum Plate COMSOL
Background Manufacturers use a modern welding method called friction stir welding to join aluminum plates A rotating tool moves along the weld joint and softens aluminum by generating frictional heat. The rotation then stirs the softened aluminum so that the two plates are joined This method allows dissimilar materials and plastics to be welded together The result is a pore-free weld joint without residual stresses due to shrinkage Heat transfer between the rotating tool and the plate during welding is considered in this model
Model Definition A symmetry is introduced to reduce the computational cost Instead of modeling the tool as a moving heat source, a moving coordinate system fixed to the tool axis is used Two infinite element domains , before and after the welding zone, are used to model an infinitely long plate The rotating tool is divided into two parts: a pin with an inner contact, and a shoulder with a contact surface on the plate. The shoulder itself is not represented Model geometry
Model Definition Heat fluxes from friction with the rotating tool are taken into account on both contact surfaces. They account for the rotating speed and the normal force The heat fluxes from friction are set to 0 if the temperature exceeds the melting temperature Surface-to-ambient radiation as well as convection are considered on the plate The right side of the infinite plate, which corresponds to the supply side, is set to ambient temperature Model boundary conditions
Results In this configuration the maximum temperature is 935 K which is slightly higher than the melting temperature of aluminum (T=933 K) There is a thin film of aluminum that melts at the very surface in contact with the shoulder and the pin Cold material arrives on the welding tool as the plate moves The high temperatures created by the friction with the tool are then transported Isothermal contours in the domain - In blue, the area where the temperature exceeds 933 K
