Measurement and analysis of applied power, forces and material response in friction stir welding of aluminum alloy 6061

Ricardo E Avila, University of Texas at El Paso

Abstract

The process of Friction Stir Welding (FSW) 6061 aluminum alloy is investigated, with focus on the forces and power being applied in the process and the material response. The main objective is to relate measurements of the forces and power applied in the process with mechanical properties of the material during the dynamic process, based on mathematical modeling and aided by computer simulations, using the LS-DYNA software for finite element modeling. Results of measurements of applied forces and power are presented. The result obtained for applied power is used in the construction of a mechanical variational model of FSW, in which minimization of a functional for the applied torque is sought, leading to an expression for shear stress in the material. The computer simulations are performed by application of the Smoothed Particle Hydrodynamics (SPH) method, in which no structured finite element mesh is used to construct a spatial discretization of the model. The current implementation of SPH in LS-DYNA allows a structural solution using a plastic kinematic material model. This work produces information useful to improve understanding of the material flow in the process, and thus adds to current knowledge about the behavior of materials under processes of severe plastic deformation, particularly those processes in which deformation occurs mainly by application of shear stress, aided by thermoplastic strain localization and dynamic recrystallization. ^

Subject Area

Engineering, Metallurgy|Engineering, Materials Science

Recommended Citation

Avila, Ricardo E, "Measurement and analysis of applied power, forces and material response in friction stir welding of aluminum alloy 6061" (2007). ETD Collection for University of Texas, El Paso. AAI3242141.
http://digitalcommons.utep.edu/dissertations/AAI3242141

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