Memon Shabbir, Murillo-Marrodán Alberto, Lankarani Hamid M, Aghajani Derazkola Hesamoddin
Department of Mechanical Engineering, Wichita State University, Wichita, KS 67260-133, USA.
Department of Mechanics, Design and Industrial Management, University of Deusto, Avda Universidades 24, 48007 Bilbao, Spain.
Materials (Basel). 2021 Jun 28;14(13):3604. doi: 10.3390/ma14133604.
Research on T-configuration aluminum constructions effectively decreases fuel consumption, increases strength, and develops aerial structures. In this research, the effects of friction stir welding (FSW) tool offset (TO) on Al-Mg-Si alloy mixing and bonding in T-configurations is studied. The process is simulated by the computational fluid dynamic (CFD) technique to better understand the material mixing flow and the bonding between the skin and flange during FSW. According to the results, the best material flow can be only achieved at an appropriate TO. The appropriate TO generates enough material to fill the joint line and results in formation of the highest participation of the flange in the stir zone (SZ) area. The results show that, in the T-configuration, FSW joints provide raw materials from the retreating side (RS) of the flange that play a primary role in producing a sound mixing flow. The selected parameters were related to the geometric limitations of the raw sheets considered in this study. The failure point of all tensile samples was located on the flange. Surface tunneling is the primary defect in these joints, which is produced at high TOs. Among the analyzed cases, the most robust joint was made at +0.2 mm TO on the advancing side (AS), resulting in more than 60% strength of the base aluminum alloy being retained.
对T型结构铝构件的研究有效地降低了燃料消耗、提高了强度并开发了航空结构。在本研究中，研究了搅拌摩擦焊（FSW）工具偏移量（TO）对T型结构中Al-Mg-Si合金混合与结合的影响。采用计算流体动力学（CFD）技术对该过程进行模拟，以更好地理解搅拌摩擦焊过程中材料的混合流动以及蒙皮与翼缘之间的结合情况。根据结果，只有在合适的工具偏移量下才能实现最佳的材料流动。合适的工具偏移量会产生足够的材料来填充焊缝，并使翼缘在搅拌区（SZ）区域的参与度达到最高。结果表明，在T型结构中，搅拌摩擦焊接头从翼缘的后退侧（RS）提供原材料，这些原材料在产生良好的混合流动中起主要作用。所选参数与本研究中所考虑的原始板材的几何限制有关。所有拉伸试样的失效点均位于翼缘上。表面隧道效应是这些接头的主要缺陷，它在高工具偏移量下产生。在分析的案例中，在前进侧（AS）工具偏移量为+0.2 mm时制成的接头最坚固，保留了超过60%的基体铝合金强度。
