Skip to main content
SpringerLink
Log in

Numerical Simulation of Heat Flow in Friction Stud Welding of Dissimilar Metals

  • Research Article - Mechanical Engineering
  • Published:
Arabian Journal for Science and Engineering Aims and scope Submit manuscript

Abstract

Friction stud welding is a solid-state joining technique used for welding similar and dissimilar materials with high integrity. In friction stud welding, heat is generated by the conversion of mechanical energy into thermal energy at the interface of the work pieces during rotation under pressure. This complicated metallurgical process is accompanied by frictional heat generation, plastic deformation, cooling of high-temperature metal, and solid-state phase variation. Since the thermal cycle of friction stud welding is very short, simulation becomes a vital role to study the behaviour of materials. The simulations make it possible to observe the temperature distribution and heat transfer fields that take place during the process. In the present work, a three-dimensional nonlinear Finite Element-based heat flow model is developed for friction stud welding of aluminium and mild steel combination. The numerical model is validated with a temperature history at the weld interface measured using a non-contact-type infrared thermometer. During friction stud welding, temperature, temperature distribution, temperature gradient, heat transfer rate and their variations, govern welding parameters of a welding machine. Knowledge of them helps to determine optimum parameters and ways to improve the design and manufacture of welding machines. Hence, the developed numerical model could be used as a tool to study the thermal cycles during the process and it will be very much useful for the subsequent analysis of residual stress and distortion of welded joints.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Wallace, F.J.; et. al.: Welding Handbook 3, 7th edn. American Welding Society, Miami, pp. 240–245 (1980)

  2. Ellis, C.R.G.; Nicholas, E.D.: A Quality Monitor for Friction Welding. The Welding Institute, Great Britain, pp. 14–18 (1975)

  3. Kulekci, M.K.; Kaluc, E.; Sik, A.; Basturk, O.: Experimental comparison of MIG and friction stir welding processes for EN AW-6061-T6 (Al Mg Si Cu) aluminium alloy. Arab. J. Sci. Eng. 35(1B), 321–330, April (2009)

    Google Scholar 

  4. Cheng, C.J.: Tranisent temperature distribution during friction welding of two similar parts. Weld. J. 41(12), 542–550 (1962)

    Google Scholar 

  5. Cheng, C.J.: Transient temperature distribution of two dissimilar materials in tubular form. Weld. J. 42(5), 233–240 (1963)

    Google Scholar 

  6. Wang, K.K.; Nagappan, P.: Transient temperature distribution in inertia welding of steels. Weld. J. 49, 419–426 (1970)

    Google Scholar 

  7. Wang, K.K.; Lin, W.: Flywheel friction welding research. Weld. J. 53, 233–242 (1974)

    Google Scholar 

  8. Kleiber, M.; Sluzalec A.: Finite element analysis of heat flow in friction welding. Eng. Trans. 32, 107–113 (1984)

    Google Scholar 

  9. Sluzalec, A.: Thermal effects in friction welding. Int. J. Mech. Sci. 32(6), 467–478 (1990)

    Google Scholar 

  10. Moal, A.; Massoni, E.: Finite element simulation of the inertia welding of two similar parts. Eng. Comput. 12(6), 497–512 (1995)

    Google Scholar 

  11. Vairis, A.; Frost, M.: Modeling the linear friction welding of titanium block. J. Mater. Sci. Eng. A292, 8–17 (2000)

    Google Scholar 

  12. Fu, L.; Duan, L.Y.; Du, S.G.: Numerical simulation of inertia friction welding process by finite element method. Weld. J. 65-S–70-S (2003)

  13. Sahin, M.: Simulation of friction welding using a developed computer program. J. Mater. Process. Technol. 153–154, 1011–1018 (2004)

    Google Scholar 

  14. Akbari Mousavi, S.A.A.; Rahbar Kelishami, A.: Experimental and numerical analysis of the friction welding process for the 4340 steel and mild steel combinations. Weld. J. 87, 178s–186s (2008)

    Google Scholar 

  15. Seli, H.; et.al.: Mechanical evaluation and thermal modelling of friction welding of mild steel and aluminium. J. Mater. Process. Technol. 210, 1209–1216 (2010)

    Google Scholar 

  16. Miller, S.F.; Wang, H.; Shih, A.J.; Li, R.: Experimental and numerical analysis of the friction drilling process. J. Manuf. Sci. Eng. 128(3), 802–810 (2006). doi:10.1115/1.2193554

    Google Scholar 

  17. Mohammed, M.B.; Bennett, C.J.; Shipway, P.H.; Hyde, T.H.: Optimization of heat transfer in the finite element process modelling of inertia friction welding of SCMV and AerMet 100. WIT Trans. Eng. Sci. 68, 253–265 (2010)

    Google Scholar 

  18. Sahin, A.Z.; Yilbas, B.S.; Ahmed, M.; Nickel, J.: Analysis of the friction welding process in relation to the welding of copper and steel bars. J. Mater. Process. Technol. 82(1–3), 127–136, October (1998)

    Google Scholar 

  19. Sahin, A.Z.: A 3D numerical study of heat conduction in friction welding process. Math. Comput. Appl. 1(2), 111–116 (1996)

    MATH  Google Scholar 

  20. Rajesh Jesudoss Hynes, N.; Nagaraj, P.; Angela Jennifa Sujana, J.: Investigation on joining of aluminium and mild steel by friction stud welding. Mater. Manuf. Process. 27(12), 1409–1413 (2012)

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Mepco Schlenk Engineering College, Sivakasi, 626 005, Tamil Nadu, India

    N. Rajesh Jesudoss Hynes, P. Nagaraj & C. A. K. Arumugham

  2. Department of Mechanical Engineering, Sudharsan Engineering College, Sathiyamangalam, Pudukkottai District, 622501, Tamil Nadu, India

    R. Palanichamy

  3. Department of Information Technology, Mepco Schlenk Engineering College, Sivakasi, 626 005, Tamil Nadu, India

    J. Angela Jennifa Sujana

Authors
  1. N. Rajesh Jesudoss Hynes
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. P. Nagaraj
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. R. Palanichamy
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. C. A. K. Arumugham
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. J. Angela Jennifa Sujana
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to N. Rajesh Jesudoss Hynes.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Rajesh Jesudoss Hynes, N., Nagaraj, P., Palanichamy, R. et al. Numerical Simulation of Heat Flow in Friction Stud Welding of Dissimilar Metals. Arab J Sci Eng 39, 3217–3224 (2014). https://doi.org/10.1007/s13369-013-0932-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s13369-013-0932-3

Keywords

Search

Navigation