Torque, power requirement and stir zone geometry in friction stir

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1、Availableonlineatwww.sciencedirect.comScriptaMaterialia60(2009)13–16www.elsevier.com/locate/scriptamatTorque,powerrequirementandstirzonegeometryinfrictionstirweldingthroughmodelingandexperimentsaaba,*A.Arora,R.Nandan,A.P.ReynoldsandT.DebRoyaDepartmentofMaterialsSciencean

2、dEngineering,ThePennsylvaniaStateUniversity,PA,USAbDepartmentofMechanicalEngineering,UniversityofSouthCarolina,SC,USAReceived10July2008;revised13August2008;accepted14August2008Availableonline26August2008Thetorque,powerrequirementandstirzonegeometryduringfrictionstirweldi

3、ngofAA2524aluminumalloyweremodeledbysolvingtheequationsofconservationofmass,momentumandenergy.Themodelpredictionsagreedwellwiththecorrespondingmeasuredvaluesforawiderangeofweldingspeedsandtoolrotationalspeedswhentheheattransfercoefficientandthefrictioncoefficientvaluesweread

4、justed.Ó2008PublishedbyElsevierLtd.onbehalfofActaMaterialiaInc.Keywords:Frictionstirwelding;Convection;Plasticdeformation;Modelling;AluminumalloysAlthoughseveralnumericalmodelsoffrictionstirThetemperatureandvelocityfieldsweresolvedwelding(FSW)havebeendevelopedforthecalcul

5、ationassumingsteady-statebehavior.Theplasticflowinaofheatgenerationrate[1–3]andheattransferandmate-three-dimensionalCartesiancoordinatesystemisrepre-rialsflow[3–14],theirtestinghas,forthemostpart,sentedbythemomentumconservationequationinindi-beenlimitedtocomparisonofthenum

6、ericallypredictedcialnotation,withiorj=1,2and3,representingthetemperaturevs.timeplotswiththecorrespondingexper-orthogonaldirections[5,8,14]imentaldata.Arigorousvalidationofnumericalmodelsouiujopooujouioujmustincludeexaminationofmodelcapabilitiestopre-q¼þlþlqU1ð1Þoxio

7、xjoxioxioxjox1dictseveralimportantfeaturesofFSWsuchasthetor-que,powerneededforweldingandthegeometryofthewhereuisthevelocity,qisthedensity,listhenon-New-stirzoneasafunctionofimportantweldingvariablestonianviscosity,U1istheweldingvelocityandpistheoverawiderangeofvalues.Her

8、eweshowthatthemod-pressure.Viscositywasdeterminedfromflowstressandelpredictionsofthestirzonegeometry,tor