November 28, 2020

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Residual Stresses in Friction Stir Welding

Residual Stresses in Friction Stir Welding
Author : Nilesh Kumar,Rajiv S. Mishra,John A. Baumann
Publisher : Butterworth-Heinemann
Release Date : 2013-11-20
Category : Technology & Engineering
Total pages :60
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This book describes the fundamentals of residual stresses in friction stir welding and reviews the data reported for various materials. Residual stresses produced during manufacturing processes lead to distortion of structures. It is critical to understand and mitigate residual stresses. From the onset of friction stir welding, claims have been made about the lower magnitude of residual stresses. The lower residual stresses are partly due to lower peak temperature and shorter time at temperature during friction stir welding. A review of residual stresses that result from the friction stir process and strategies to mitigate it have been presented. Friction stir welding can be combined with additional in-situ and ex-situ manufacturing steps to lower the final residual stresses. Modeling of residual stresses highlights the relationship between clamping constraint and development of distortion. For many applications, management of residual stresses can be critical for qualification of component/structure. Reviews magnitude of residual stresses in various metals and alloys Discusses mitigation strategies for residual stresses during friction stir welding Covers fundamental origin of residual stresses and distortion

Residual Stress in Friction Stir Welding and Laser-Assisted Friction Stir Welding by Numerical Simulation and Experiments

Residual Stress in Friction Stir Welding and Laser-Assisted Friction Stir Welding by Numerical Simulation and Experiments
Author : Caterina Casavola
Publisher : Unknown
Release Date : 2018
Category : Technology
Total pages :129
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The friction stir welding (FSW) has become an important welding technique to join materials that are difficult to weld by traditional fusion welding technology. In this technique, the material is not led to fusion, and the joint is the result of the rotation and movement along the welding line of the tool that causes softening of material due to frictional heat and the stirring of the same. In FSW, the temperature does not reach the fusion value of the materials, and this helps to decrease the residual stress values. However, due to the higher force involved in the weld and, thus, the rigid clamping used, the residual stresses are not low in general in this technique. As the presence of high residual stress values influences the post-weld mechanical properties, e.g. fatigue properties, it is important to investigate the residual stress distribution in the FSW welds. In this chapter, two numerical models that predict temperatures and residual stresses in friction stir welding and laser-assisted friction stir welding will be described. Experimental measurements of temperatures and residual stress will be carried out to validate the prediction of the models.

Residual Stress Analysis on Welded Joints by Means of Numerical Simulation and Experiments

Residual Stress Analysis on Welded Joints by Means of Numerical Simulation and Experiments
Author : Paolo Ferro,Filippo Berto
Publisher : BoD – Books on Demand
Release Date : 2018-05-16
Category : Technology & Engineering
Total pages :162
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The ability to quantify residual stresses induced by welding processes through experimentation or numerical simulation has become, today more than ever, of strategic importance in the context of their application to advanced design. This is an ongoing challenge that commenced many years ago. Recent design criteria endeavour to quantify the effect of residual stresses on fatigue strength of welded joints to allow a more efficient use of materials and a greater reliability of welded structures. The aim of the present book is contributing to these aspects of design through a collection of case-studies that illustrate both standard and advanced experimental and numerical methodologies used to assess the residual stress field in welded joints. The work is intended to be of assistance to designers, industrial engineers and academics who want to deepen their knowledge of this challenging topic.

Friction Stir Welding and Processing X

Friction Stir Welding and Processing X
Author : Yuri Hovanski,Rajiv Mishra,Yutaka Sato,Piyush Upadhyay,David Yan
Publisher : Springer
Release Date : 2019-02-11
Category : Technology & Engineering
Total pages :283
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This book is a compilation of the recent progress on friction stir technologies including high-temperature applications, industrial applications, dissimilar alloy/materials, lightweight alloys, simulation, control, characterization, and derivative technologies. The volume offers a current look at friction stir welding technology from application to characterization and from modeling to R&D. Contributions document advances in application, controls, and simulation of the friction stir process to aid researchers in seeing the current state-of-the-art.

Friction Stir Welding

Friction Stir Welding
Author : Daniela Lohwasser,Zhan Chen
Publisher : Elsevier
Release Date : 2009-12-18
Category : Technology & Engineering
Total pages :436
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Friction stir welding (FSW) is a highly important and recently developed joining technology that produces a solid phase bond. It uses a rotating tool to generate frictional heat that causes material of the components to be welded to soften without reaching the melting point and allows the tool to move along the weld line. Plasticized material is transferred from the leading edge to trailing edge of the tool probe, leaving a solid phase bond between the two parts. Friction stir welding: from basics to applications reviews the fundamentals of the process and how it is used in industrial applications. Part one discusses general issues with chapters on topics such as basic process overview, material deformation and joint formation in friction stir welding, inspection and quality control and friction stir welding equipment requirements and machinery descriptions as well as industrial applications of friction stir welding. A chapter giving an outlook on the future of friction stir welding is included in Part one. Part two reviews the variables in friction stir welding including residual stresses in friction stir welding, effects and defects of friction stir welds, modelling thermal properties in friction stir welding and metallurgy and weld performance. With its distinguished editors and international team of contributors, Friction stir welding: from basics to applications is a standard reference for mechanical, welding and materials engineers in the aerospace, automotive, railway, shipbuilding, nuclear and other metal fabrication industries, particularly those that use aluminium alloys. Provides essential information on topics such as basic process overview, materials deformation and joint formation in friction stir welding Inspection and quality control and friction stir welding equipment requirements are discussed as well as industrial applications of friction stir welding Reviews the variables involved in friction stir welding including residual stresses, effects and defects of friction stir welds, modelling thermal properties, metallurgy and weld performance

Current Trends in Friction Stir Welding (FSW) and Friction Stir Spot Welding (FSSW)

Current Trends in Friction Stir Welding (FSW) and Friction Stir Spot Welding (FSSW)
Author : Mukuna Patrick Mubiayi,Esther Titilayo Akinlabi,Mamookho Elizabeth Makhatha
Publisher : Springer
Release Date : 2018-08-09
Category : Technology & Engineering
Total pages :206
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This book provides an overview of friction stir welding and friction stir spot welding with a focus on aluminium to aluminium and aluminium to copper. It also discusses experimental results for friction stir spot welding between aluminium and copper, offering a good foundation for researchers wishing to conduct more investigations on FSSW Al/Cu. Presenting full methodologies for manufacturing and case studies on FSSW Al/Cu, which can be duplicated and used for industrial purposes, it also provides a starting point for researchers and experts in the field to investigate the FSSW process in detail. A variant of the friction stir welding process (FSW), friction stir spot welding (FSSW) is a relatively new joining technique and has been used in a variety of sectors, such as the automotive and aerospace industries. The book describes the microstructural evolution, chemical and mechanical properties of FSW and FSSW, including a number of case studies.

Friction Stir Welding and Processing

Friction Stir Welding and Processing
Author : Rajiv Sharan Mishra,Partha Sarathi De,Nilesh Kumar
Publisher : Springer
Release Date : 2014-08-04
Category : Technology & Engineering
Total pages :338
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This book lays out the fundamentals of friction stir welding and processing and builds toward practical perspectives. The authors describe the links between the thermo-mechanical aspects and the microstructural evolution and use of these for the development of the friction stir process as a broader metallurgical tool for microstructural modification and manufacturing. The fundamentals behind the practical aspects of tool design, process parameter selection and weld related defects are discussed. Local microstructural refinement has enabled new concepts of superplastic forming and enhanced low temperature forming. The collection of friction stir based technologies is a versatile set of solid state manufacturing tools.

Influence of the Clamps Configuration on Residual Stresses Field in Friction Stir Welding Process

Influence of the Clamps Configuration on Residual Stresses Field in Friction Stir Welding Process
Author : Anonim
Publisher : Unknown
Release Date : 2015
Category :
Total pages :129
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Friction stir welding is a joining process developed in 1991 by The Welding Institute. This welding technique is a solid-state joining process leading to joints with good mechanical performance and low residual stresses. In all welding techniques, the clamping systems have an important role in determining the quality of the welds and mechanical characteristics. Even more in friction stir welding, the position of the clamps plays a critical role because it is mainly a mechanical process with high forces involved. In this article, the correlation between the residual stress field and configurations of clamps has been established numerically. For this purpose an uncoupled thermo-mechanical finite element analysis has been carried out. The mechanical loads due to the tool have been also implemented into the model. The thermal and mechanical models have been validated on temperature field recorded by an infrared camera and residual stress field measured by X-ray diffraction analysis. The friction stir welding test was conducted on 6-mm-thick 5754 H111 aluminium alloy plates.

Advances in Friction-Stir Welding and Processing

Advances in Friction-Stir Welding and Processing
Author : M.-K. Besharati-Givi,P. Asadi
Publisher : Elsevier
Release Date : 2014-12-08
Category : Technology & Engineering
Total pages :796
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Friction-stir welding (FSW) is a solid-state joining process primarily used on aluminum, and is also widely used for joining dissimilar metals such as aluminum, magnesium, copper and ferrous alloys. Recently, a friction-stir processing (FSP) technique based on FSW has been used for microstructural modifications, the homogenized and refined microstructure along with the reduced porosity resulting in improved mechanical properties. Advances in friction-stir welding and processing deals with the processes involved in different metals and polymers, including their microstructural and mechanical properties, wear and corrosion behavior, heat flow, and simulation. The book is structured into ten chapters, covering applications of the technology; tool and welding design; material and heat flow; microstructural evolution; mechanical properties; corrosion behavior and wear properties. Later chapters cover mechanical alloying and FSP as a welding and casting repair technique; optimization and simulation of artificial neural networks; and FSW and FSP of polymers. Provides studies of the microstructural, mechanical, corrosion and wear properties of friction-stir welded and processed materials Considers heat generation, heat flow and material flow Covers simulation of FSW/FSP and use of artificial neural network in FSW/FSP

Residual Stresses IX

Residual Stresses IX
Author : M. Francois,Guillaume Montay,Benoit Panicaud,Delphine Retraint,Emmanuelle Rouhaud
Publisher : Trans Tech Publications Ltd
Release Date : 2014-08-11
Category : Technology & Engineering
Total pages :1010
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Collection of selected, peer reviewed papers from the 9th European Conference on Residual Stresses, ECRS-9, July 7-10, 2014, Troyes, France. Volume is indexed by Thomson Reuters CPCI-S (WoS). The 157 papers are grouped as follows: Chapter I. Measurement Methods, I.1. Local Scale Measurements, I.2. Diffraction at Grain Scale and Multiscale Diffraction, I.3. Diffraction: Gradients and Instrumental Developments, I.4. Mechanical Relaxation Methods, I.5. Acoustics and Electromagnetics Methods, Chapter II. Manufacturing and Materials Processing, II.1. Welding, II.2. Heat Treatment and Phase Transformation, II.3. Machining and Cold Work, Chapter III. Materials and Structures, III.1. Fatigue and Fracture, III.2. Films, Coatings and Oxides, III.3. Composites and Nano/Micro Structures

Optimization in Friction Stir Welding

Optimization in Friction Stir Welding
Author : Cem Celal Tutum
Publisher : LAP Lambert Academic Publishing
Release Date : 2011-02
Category : Friction stir welding
Total pages :232
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This book deals with the challenging multidisciplinary task of combining variant thermal and thermo-mechanical simulations for the manufacturing process of friction stir welding (FSW) with numerical optimization techniques in the search for optimal process parameters. The FSW process is characterized by multiphysics involving solid material flow, heat transfer, thermal softening, recrystallization and the formation of residual stresses. Initially, the thermal models were addressed since they in essence constitute the basis of all other models of FSW. Following this, several integrated thermo-mechanical models of the process were developed to simulate temperature and stress evolution during welding and subsequent cooling, i.e. eventually leading to the residual stress state and reduced mechanical properties, as well as to predict the final weld's load carrying capacity. These models were finally combined with classical single-objective and evolutionary multi-objective optimization algorithms (i.e. SQP and NSGA-II), to find the optimum process parameters (heat input, rotational and traverse welding speeds) that would result in favorable thermo-mechanical conditions for the process.

Measurement of Residual and Applied Stress Using Neutron Diffraction

Measurement of Residual and Applied Stress Using Neutron Diffraction
Author : M.T. Hutchings,Aaron D. Krawitz
Publisher : Springer Science & Business Media
Release Date : 2012-12-06
Category : Technology & Engineering
Total pages :588
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The accurate, absolute, and non-destructive measurement of residual stress fields within metallic, ceramic, and composite engineering components has been one of the major problems facing engineers for many years, and so the extension of X-ray methods to the use of neutrons represents a major advance. The technique utilizes the unique penetrating power of the neutron into most engineering materials, combined with the sensitivity of diffraction, to measure the separation of lattice planes within grains of polycrystalline engineering materials, thus providing an internal strain gauge. The strain is then converted to stress using calibrated elastic constants. It was just over ten years ago that the initial neutron diffraction measurements of residual stress were carried out, and during the ensuing decade measurements have commenced at most steady state reactors and pulsed sources around the world. So swift has been the development of the field that, in addition to fundamental scientific studies, commercial measurements have been made on industrial components for several years now. The use of neutrons is ideally suited to the determination of triaxial macrostress tensors, macrostress gradients, and microstresses in composites and multiphase alloys as well as deformed, plastically anisotropic metals and alloys. To date, it has been used to investigate welded and heat-treated industrial components, to characterize composites, to study the response of material under applied loads, to calibrate more portable methods such as ultrasonics, and to verify computer modelling calculations of residual and applied stress.

Trends in Welding Research

Trends in Welding Research
Author : Stan A. David
Publisher : ASM International
Release Date : 2009-01-01
Category : Technology & Engineering
Total pages :815
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Advanced Welding and Micro Joining / Packaging for the 21st Century

Advanced Welding and Micro Joining / Packaging for the 21st Century
Author : Chang Hee Lee,Jong Bong Lee,Dong Hwan Park,Suck Joo Na
Publisher : Trans Tech Publications Ltd
Release Date : 2008-06-12
Category : Technology & Engineering
Total pages :720
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Volume is indexed by Thomson Reuters CPCI-S (WoS). The aim of this special collection of papers on the theme of “Advanced Welding and Micro Joining/Packaging for the 21st Century” was to review and analyze the state-of-the-art concerning the welding and joining/packaging technologies which are essential to the production of structures ranging from the compact to the ultra-large.

Friction Stir Welding of Dissimilar Alloys and Materials

Friction Stir Welding of Dissimilar Alloys and Materials
Author : Nilesh Kumar,Rajiv S. Mishra,Wei Yuan
Publisher : Butterworth-Heinemann
Release Date : 2015-03-05
Category : Technology & Engineering
Total pages :134
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This book will summarize research work carried out so far on dissimilar metallic material welding using friction stir welding (FSW). Joining of dissimilar alloys and materials are needed in many engineering systems and is considered quite challenging. Research in this area has shown significant benefit in terms of ease of processing, material mixing, and superior mechanical properties such as joint efficiencies. A summary of these results will be discussed along with potential guidelines for designers. Explains solid phase process and distortion of work piece Addresses dimensional stability and repeatability Addresses joint strength Covers metallurgical properties in the joint area Covers fine microstructure Introduces improved materials use (e.g., joining different thicknesses) Covers decreased fuel consumption in light weight aircraft Addresses automotive and ship applications