Process parameters and base material thermal properties strongly affect peak temperature evolution in friction stir welding (FSW). This work develops a semi-empirical model for peak temperature estimation during FSW of aluminium alloys. Several bead-on-plate runs were conducted on AA5083-H111, AA6082-T6 and AA7075-T6. Different rotational and welding speeds were tested while measuring the temperature with a thermocouple embedded in the tool. A polynomial model was proposed with the model's coefficients strongly correlating to the material thermal properties. Additionally, a threshold peak temperature was defined to avoid cold defects by combining temperature measurements with joint quality information obtained from X-ray scans. The efficiency of the model and the defined threshold are proven by applying them to the literature.
ThreadgilllPL, LeonardAJ, ShercliffHR, et al. Friction stir welding of aluminium alloys. Int Mater Rev. 2009; 54(2):49–93.
3.
AmbrosioD, WagnerV, DesseinG, et al. Plastic behavior-dependent weldability of heat-treatable aluminum alloys in friction stir welding. Int J Adv Manuf Technol. 2021; 117:635–652.
4.
AmbrosioD, GarnierC, WagnerV, et al. Relationships between welding parameters, aging conditions, and weld properties in AA7075-T6 friction stir welds. Int J Adv Manuf Technol. 2020; 111(5–6):1333–1350.
5.
NieL, WuYX, GongH.Prediction of temperature and residual stress distributions in friction stir welding of aluminum alloy. Int J Adv Manuf Technol. 2020; 106(7–8):3301–3310.
6.
HuntJB, PearlD, HovanskiY, et al. Preliminary investigation of the effect of temperature control in friction stir welding. In: Hovanski Y, Sato Y, Upadhyay P, Naumov AA, Kumar N, editors. Friction stir welding and processing XI. Cham: Springer International Publishing; 2021. p. 81–89.
7.
SilvaAC, De BackerJ, BolmsjöG.Temperature measurements during friction stir welding. Int J Adv Manuf Technol. 2017; 88(9–12):2899–2908.
8.
MasakiK, SatoYS, MaedaM, et al. Experimental simulation of recrystallized microstructure in friction stir welded Al alloy using a plane-strain compression test. Scr Mater. 2008; 58(5):355–360.
9.
AssidiM, FourmentL, GuerdouxS, et al. Friction model for friction stir welding process simulation: calibrations from welding experiments. Int J Mach Tools Manuf. 2010; 50(2):143–155. doi:10.1016/j.ijmachtools.2009.11.008
10.
FehrenbacherA, DuffieNA, FerrierNJ, et al. Effects of tool-workpiece interface temperature on weld quality and quality improvements through temperature control in friction stir welding. Int J Adv Manuf Technol. 2014; 71(1-4):165–179.
11.
GerlichA, Avramovic-CingaraG, NorthTH.Stir zone microstructure and strain rate during Al 7075-T6 friction stir spot welding. Metall Mater Trans A: Phys Metall Mater Sci. 2006; 37(9):2773–2786.
12.
ArbegastWJ, HartleyPJ.Proceedings of the 5th International Conference of Trends in Welding Research. June. Pine Mountain, GA. 1998.
13.
RoyGG, NandanR, DebRoyT.Dimensionless correlation to estimate peak temperature during friction stir welding. Sci Technol Weld Join. 2006; 11(5):606–608.
14.
BuckinghamE.On physically similar systems: illustrations of the use of dimensional equations. Phys Rev. 1914; 4(4):345–376.
15.
HamiltonC, DymekS, SommersA.Characteristic temperature curves for aluminum alloys during friction stir welding. Weld J (Miami, Fla). 2010; 89(9):189–194.
16.
QianJ, OuY, LiJ, et al. An analytical model to calculate the peak temperature for friction stir welding. Sci Technol Weld Join. 2017; 22(6):520–525. doi:10.1080/13621718.2016.1268367
17.
SheppardT, WrightDS.Determination of flow stress: part 1 constitutive equation for aluminium alloys at elevated temperatures. Metals Technol. 1979; 6(1):215–223. doi:10.1179/030716979803276264
18.
AmbrosioD, DesseinG, WagnerV, et al. On the potential applications of acoustic emission in friction stir welding. J Manuf Process. 2022 Dec; 75:461–475. doi:10.1016/j.jmapro.2022.01.012
19.
ShahP, BadhekaV.An experimental investigation of temperature distribution and joint properties of Al 7075 T651 friction stir welded aluminium alloys. Procedia Technol. 2016; 23:543–550.
20.
ASM Handbook. Properties and selection: nonferrous Alloys and special-purpose materials. Vol. 2. Ohio: ASM International; 1990.
21.
Silva-MagalhãesA, De BackerJ, MartinJ, et al. In-situ temperature measurement in friction stir welding of thick section aluminium alloys. J Manuf Process. 2019 Feb; 39:12–17. doi:10.1016/j.jmapro.2019.02.001
22.
LohwasserD, ChenZ.Friction stir welding from basics to applications. Cambridgem, UK: Woodhead Publishing Limited; 2010.
AmbrosioD, WagnerV, GarnierC, Influence of welding parameters on the microstructure, thermal fields and defect formation in AA7075-T6 friction stir welds. Welding in the World. 2020; 64(5):773–784. doi:10.1007/s40194-020-00869-4
