Finite Element Analysis of Friction Stir Welded Aluminum Alloy AA6061-T6 Joints

Hüseyin Tarik Serindağ; Binnur Goren Kiral; Zeki Alper Kadayifçi

doi:10.3139/120.110653

Article

Finite Element Analysis of Friction Stir Welded Aluminum Alloy AA6061-T6 Joints

Hüseyin Tarik Serindağ , Binnur Goren Kiral and Zeki Alper Kadayifçi

Published/Copyright: November 20, 2014

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From the journal Materials Testing Volume 56 Issue 11-12

Abstract

The aim of this study was to develop a finite element model for predicting the transient temperature and stress fields during friction stir welding. For this purpose, a three-dimensional model based on the nonlinear finite element analysis (FEA) has been generated. The experimentally measured temperatures by using an infrared thermometer during experiments were compared to the results obtained by FEA. In the numerical simulations, mechanical and physical properties were considered depending on temperature. The effect of the rotational and transverse speeds on the distribution of temperature and stresses in the welded AA6061-T6 plates were examined. It was observed that the maximum temperature near the weld region increases with increasing rotational speed. The normal stresses, σ_x and σ_y also increase as the rotational speed increases. The temperature decreases as the tool transverse speed increases.

Kurzfassung

Das Ziel der diesem Beitrag zugrunde liegenden Studie bestand darin, ein Finite-Element-Modell zur Vorhersage der transienten Temperatur- und Spannungsfelder während des Rührreibschweißens zu entwickeln. Für diesen Zweck wurde ein dreidimensionales Modell basierend auf einer nicht-linearen Finite-Element-Analyse generiert. Die experimentell mittels eines Infrarotthermometers gemessenen Temperaturen wurden mit den Ergebnissen der Finite-Element-Analyse verglichen. In den Finite-Element-Analysen wurden die mechanischen und physikalischen Eigenschaften in Abhängigkeit der Temperatur berücksichtigt. Es wurde die Auswirkung der Rotations- und transversalen Geschwindigkeit auf die Verteilung der Temperaturen und Spannungen in den geschweißten AA6061-T6-Blechen untersucht. Es wurde beobachtet, dass die maximale Temperatur nahe der Schweißverbindung mit zunehmender Rotationsgeschwindigkeit zunimmt. Die Normalspannungen σ_x and σ_y steigen ebenfalls mit zunehmender Rotationsgeschwindigkeit an. Die Temperatur nimmt ab, wenn die transversale Werkzeuggeschwindigkeit ansteigt.

Keywords: Materials testing; AA6061-T6; friction stir welding; finite element method

*Correspondence Address, Associate Prof. Dr. Binnur Goren Kiral, Dokuz Eylul University, Faculty of Engineering, Department of Mechanical Engineering, 35397, Buca-Izmir, Turkey. E-mail: binnur.goren@deu.edu.tr

Hüseyin Tarik Serindag, born in 1980, received his MSc from Mustafa Kemal University in Antakya, Turkey, in 2006. He is currently working as a research assistant and doing his PhD on numerical modeling of friction stir welding at Dokuz Eylül University in Izmir, Turkey. His main research areas are friction stir welding and finite element analyses.

Dr. Binnur Goren Kiral, born in 1971, received her MSc and PhD degrees from Dokuz Eylul University, Izmir, Turkey. She carried out her research work for her PhD at the Helmholtz Center Geesthacht in Germany. She is currently working as an associate professor at Dokuz Eylül University. Her main research areas are finite element modeling and analyses as well as stability and fracture of welded materials.

Zeki Alper Kadayifci, born in 1990, graduated in Mechanical Engineering from Dokuz Eylul University, Izmir, Turkey, in 2011. He has received his MSc from the same university in 2013. His main research areas are friction stir welding and computer-aided design.

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Published Online: 2014-11-20

Published in Print: 2014-11-17

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https://doi.org/10.3139/120.110653

Keywords for this article

Materials testing; AA6061-T6; friction stir welding; finite element method