A review on phenomenological model subtleties for defect assessment in friction stir welding

Friction stir welding (FSW) is in existence for well over three decades. Started primarily with the joining of aluminium alloys, FSW is gradually engaged for other alloys and also examined for additive manufacturing. The conventional experimental and theoretical studies on FSW focus on finding proce...

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Published inJournal of manufacturing processes Vol. 120; pp. 641 - 679
Main Authors Das, Debtanay, Bag, Swarup, Pal, Sukhomay, De, Amitava
Format Journal Article
LanguageEnglish
Published Elsevier Ltd 30.06.2024
Subjects
Arbitrary Lagrangian Eulerian (ALE)
Computational fluid dynamics (CFD)
Coulomb's friction law
Coupled Eulerian and Lagrangian (CEL)
Flash formation
FSW
Hook defect
Johnson-Cook model
Kissing bond defect
Lack of penetration
Norton's friction law
Norton-Hoff model
Nugget collapse
Sheppard-Wright model
Smoothed particle hydrodynamics (SPH)
Surface galling
Tresca's friction law
Tunnel defect
Voids
Wormhole
Wormhole
Tunnel defect
Computational fluid dynamics (CFD)
Kissing bond defect
Coupled Eulerian and Lagrangian (CEL)
FSW
Sheppard-Wright model
Arbitrary Lagrangian Eulerian (ALE)
Voids
Johnson-Cook model
Lack of penetration
Hook defect
Surface galling
Flash formation
Coulomb's friction law
Smoothed particle hydrodynamics (SPH)
Norton's friction law
Tresca's friction law
Nugget collapse
Norton-Hoff model
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Abstract Friction stir welding (FSW) is in existence for well over three decades. Started primarily with the joining of aluminium alloys, FSW is gradually engaged for other alloys and also examined for additive manufacturing. The conventional experimental and theoretical studies on FSW focus on finding process parameters and tool geometry for producing a weld joint and ignores the insight for the evolution of defects. An appropriate comprehension of the mechanistic models to realize the underlying phenomena for the evolution of defects and assess their susceptibility to occur is required to enhance the application of FSW process. We present here a comprehensive review of the mechanistic models and, the constitutive and empirical relations with a focus on their substantive use for understanding the evolution of defects in FSW. Several associated factors such as tool-material interaction, computational complexity and accuracy, and the utility of commercial software are examined to present the subject. A thoughtful understanding about the mechanism of surface and volumetric defects is targeted through phenomenological behaviour of the process. We believe that this review work will provide a framework to help produce defect-free welds in FSW and allied solid-state joining processes.
AbstractList Friction stir welding (FSW) is in existence for well over three decades. Started primarily with the joining of aluminium alloys, FSW is gradually engaged for other alloys and also examined for additive manufacturing. The conventional experimental and theoretical studies on FSW focus on finding process parameters and tool geometry for producing a weld joint and ignores the insight for the evolution of defects. An appropriate comprehension of the mechanistic models to realize the underlying phenomena for the evolution of defects and assess their susceptibility to occur is required to enhance the application of FSW process. We present here a comprehensive review of the mechanistic models and, the constitutive and empirical relations with a focus on their substantive use for understanding the evolution of defects in FSW. Several associated factors such as tool-material interaction, computational complexity and accuracy, and the utility of commercial software are examined to present the subject. A thoughtful understanding about the mechanism of surface and volumetric defects is targeted through phenomenological behaviour of the process. We believe that this review work will provide a framework to help produce defect-free welds in FSW and allied solid-state joining processes.
Author De, Amitava
Das, Debtanay
Pal, Sukhomay
Bag, Swarup
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  givenname: Debtanay
  surname: Das
  fullname: Das, Debtanay
  organization: Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati 781039, Assam, India
– sequence: 2
  givenname: Swarup
  surname: Bag
  fullname: Bag, Swarup
  email: swarupbag@iitg.ac.in
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  surname: Pal
  fullname: Pal, Sukhomay
  organization: Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati 781039, Assam, India
– sequence: 4
  givenname: Amitava
  surname: De
  fullname: De, Amitava
  organization: Department of Mechanical Engineering, Indian Institute of Technology Bombay, Mumbai 400076, India
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Keywords Wormhole
Tunnel defect
Computational fluid dynamics (CFD)
Kissing bond defect
Coupled Eulerian and Lagrangian (CEL)
FSW
Sheppard-Wright model
Arbitrary Lagrangian Eulerian (ALE)
Voids
Johnson-Cook model
Lack of penetration
Hook defect
Surface galling
Flash formation
Coulomb's friction law
Smoothed particle hydrodynamics (SPH)
Norton's friction law
Tresca's friction law
Nugget collapse
Norton-Hoff model
Language English
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Snippet Friction stir welding (FSW) is in existence for well over three decades. Started primarily with the joining of aluminium alloys, FSW is gradually engaged for...
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elsevier
SourceType Enrichment Source
Index Database
Publisher
StartPage 641
SubjectTerms Arbitrary Lagrangian Eulerian (ALE)
Computational fluid dynamics (CFD)
Coulomb's friction law
Coupled Eulerian and Lagrangian (CEL)
Flash formation
FSW
Hook defect
Johnson-Cook model
Kissing bond defect
Lack of penetration
Norton's friction law
Norton-Hoff model
Nugget collapse
Sheppard-Wright model
Smoothed particle hydrodynamics (SPH)
Surface galling
Tresca's friction law
Tunnel defect
Voids
Wormhole
Title A review on phenomenological model subtleties for defect assessment in friction stir welding
URI https://dx.doi.org/10.1016/j.jmapro.2024.04.063
Volume 120
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