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Finite element modeling of continuous drive friction welding of Al6061 alloy

Mohammed A. Tashkandi

Mohammed A. Tashkandi

Faculty of Engineering, Northern Border UniversityArar, Saudi Arabia
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Tashkandi, Mohammed A.
  
May 30, 2021
Finite element modeling of continuous drive friction welding of Al6061 alloy's Cover Image
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Published Online: May 30, 2021
Page range: 1 - 14
Received: Jan 26, 2021
Accepted: Feb 21, 2021
DOI: https://doi.org/10.2478/msp-2021-0001
Keywords
© 2021 Mohammed A. Tashkandi, published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1

Rotary friction welding process.
Rotary friction welding process.

Fig. 2

Welding parameters for CDFW. [1]
Welding parameters for CDFW. [1]

Fig. 3

2D axisymmetric geometry of the workpiece.
2D axisymmetric geometry of the workpiece.

Fig. 4

a) the number of elements and fineness of the mesh and, b) convergence plot of the size of elements.
a) the number of elements and fineness of the mesh and, b) convergence plot of the size of elements.

Fig. 5

The two parts to be welded before welding.
The two parts to be welded before welding.

Fig. 6

Variation of the phase change coefficient as a function of the temperature of aluminum 6061.
Variation of the phase change coefficient as a function of the temperature of aluminum 6061.

Fig. 7

Variation in the specific heat capacity of AA6061 as a function of temperature.
Variation in the specific heat capacity of AA6061 as a function of temperature.

Fig. 8

Variation in the density of AA6061 as a function of temperature.
Variation in the density of AA6061 as a function of temperature.

Fig. 9

Variation in the thermal conductivity of AA6061 as a function of temperature.
Variation in the thermal conductivity of AA6061 as a function of temperature.

Fig. 10

Modeled process parameters for tf = 10 s.
Modeled process parameters for tf = 10 s.

Fig. 11

The temperature profile for the 12 s friction time.
The temperature profile for the 12 s friction time.

Fig. 12

Temperature profiles for different friction times; 4, 5, and 6 s, respectively.
Temperature profiles for different friction times; 4, 5, and 6 s, respectively.

Fig. 13

The temperature profile for 9 and 10 s friction times.
The temperature profile for 9 and 10 s friction times.

Fig. 14

Welding flash formation at different friction times; these are 4, 5, 6, 9, and 10 s, respectively.
Welding flash formation at different friction times; these are 4, 5, 6, 9, and 10 s, respectively.

Fig. 15

Temperature profile at the contact zone at t = 0 s.
Temperature profile at the contact zone at t = 0 s.

Fig. 16

Temperature profile at the contact zone at t = 1 s.
Temperature profile at the contact zone at t = 1 s.

Fig. 17

Temperature profile at the contact zone at t = 5 s.
Temperature profile at the contact zone at t = 5 s.

Fig. 18

The temperature profile at the contact zone at t = 10 and 11 s.
The temperature profile at the contact zone at t = 10 and 11 s.

Al6061 material properties for phase-change simulation_ [16]

Property Value
Ttrans [K] 925.15
δT [K] 50
Δhf [kJ/kg] 380
ρsolid [kg/m3] 2705
ρliquid [kg/m3] 2415
Cp,solid [J/kg·K] 870
Cp,liquid [J/kg·K] 1170
κsolidus [W/m·K] 66.5
κliquid [W/m·K] 90

CDFW process parameters_

Process Parameter Value / range
Rotational Speed (rpm) 2000
Friction Pressure (MPa) 21
Friction time (s) 4, 5, 6, 9, 10, 12

FEM boundary conditions_

Model Feature Boundary Condition
Solid Mechanics The central axis of the parts Axial Symmetry
The outer surfaces of the parts Free to deform
The Entire model Zero initial displacement
The rotating part Rigid motion suppression
The end of the fixed part Axial load
Heat Transfer T = 305 K Initial temperature
The central axis of the parts Axial symmetry
The outer surfaces of the parts Heat flux according to q0 = h · (Text − T)
Welding Parameters Rotation 0 s to tf = rotation speed, otherwise zero
Pressure 0 s to tf = applied pressure, otherwise zero

Chemical composition in weight percent of Al6061_

Element Si Fe Cu Mn Mg Zn Cr Ti Al
Wt% 0.75 0.5 0.5 0.15 0.9 0.03 0.03 0.05 Rest
Language:
English
Publication timeframe:
4 times per year
Journal Subjects:
Materials Sciences, Materials Sciences, other, Nanomaterials, Functional and Smart Materials, Materials Characterization and Properties
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