Janga Venkata Somi Reddy, Awang Mokhtar, Yamin Mohd Fadillah, Suhuddin Uceu F H, Klusemann Benjamin, Santos Jorge F Dos
Department of Mechanical Engineering, Universiti Teknologi PETRONAS, Seri Iskandar 32610, Perak, Malaysia.
Solid State Materials Processing, Institute of Materials Mechanics, Helmholtz-Zentrum Hereon, Max-Planck-Str. 1, 21502 Geesthacht, Germany.
Materials (Basel). 2021 Dec 6;14(23):7485. doi: 10.3390/ma14237485.
The refill friction stir spot welding (refill FSSW) process is a solid-state joining process to produce welds without a keyhole in spot joint configuration. This study presents a thermo-mechanical model of refill FSSW, validated on experimental thermal cycles for thin aluminium sheets of AA7075-T6. The temperatures in the weld centre and outside the welding zone at selected points were recorded using K-type thermocouples for more accurate validation of the thermo-mechanical model. A thermo-mechanical three-dimensional refill FSSW model was built using DEFORM-3D. The temperature results from the refill FSSW numerical model are in good agreement with the experimental results. Three-dimensional material flow during plunging and refilling stages is analysed in detail and compared to experimental microstructure and hardness results. The simulation results obtained from the refill FSSW model correspond well with the experimental results. The developed 3D numerical model is able to predict the thermal cycles, material flow, strain, and strain rates which are key factors for the identification and characterization of zones as well for determining joint quality.
二次填充搅拌摩擦点焊（refill FSSW）工艺是一种固态连接工艺，用于在点焊配置中生产无匙孔的焊缝。本研究提出了二次填充搅拌摩擦点焊的热-机械模型，并通过对AA7075-T6薄铝板的实验热循环进行了验证。使用K型热电偶记录选定位置处焊缝中心和焊接区外的温度，以便更准确地验证热-机械模型。使用DEFORM-3D建立了热-机械三维二次填充搅拌摩擦点焊模型。二次填充搅拌摩擦点焊数值模型的温度结果与实验结果吻合良好。详细分析了冲压和二次填充阶段的三维材料流动，并与实验微观结构和硬度结果进行了比较。二次填充搅拌摩擦点焊模型的模拟结果与实验结果对应良好。所开发的三维数值模型能够预测热循环、材料流动、应变和应变速率，这些是识别和表征区域以及确定接头质量的关键因素。
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