The current study performs an explicit nonlinear finite element simulation to predict temperature distribution and consequent stresses during the friction stir welding (FSW) of AA 7075-T651 alloy. The ABAQUS® finite element software was used to model and analyze the process steps that involve plunging, dwelling, and traverse stages. Techniques such as Arbitrary Lagrangian–Eulerian (ALE) formulation, adaptive meshing, and computational feature of mass scaling were utilized to simulate sequence events during the friction stir welding process. The contact between the welding tool and workpiece was modelled through applying Coulomb’s friction model with a nonlinear friction coefficient value. Also, the model considered the effect of nonlin

The current study performs an explicit nonlinear finite element simulation to predict temperature distribution and consequent stresses during the friction stir welding (FSW) of AA 7075-T651 alloy. The ABAQUS® finite element software was used to model and analyze the process steps that involve plunging, dwelling, and traverse stages. Techniques such as Arbitrary Lagrangian–Eulerian (ALE) formulation, adaptive meshing, and computational feature of mass scaling were utilized to simulate sequence events during the friction stir welding process. The contact between the welding tool and workpiece was modelled through applying Coulomb’s friction model with a nonlinear friction coefficient value. Also, the model considered the effect o

In this study, a 3 mm thickness 7075-T6 aluminium alloy sheet was used in the friction stir welding process. Using the design of experiment to reduce the number of experiments and to obtain the optimum friction stir welding parameters by utilizing Taguchi technique based on the ultimate tensile test results. Orthogonal array of L9 (3³) was used based on three numbers of the parameters and three levels for each parameter, where shoulder-workpiece interference depth (0.20, 0.25, and 0.3) mm, pin geometry (cylindrical thread flat end, cylindrical thread with 3 flat round end, cylindrical thread round end), and thread pitch (0.8, 1, and 1.2) mm) this technique executed by Minitab 17 software. The results showed th

The evaluation of residual stresses (RS) induced by the friction stir welding (FSW) process is crucial in anticipating the performance of the welded structure. The existence of such residual stresses within a friction stir welded structure may lead to excessive distortion and weakness to afford the applied external loads. To assess quantitatively the effect of these residual stresses generated by FSW process, the current paper implements a Coupled Eulerian–Lagrangian (CEL) finite element simulation to analyze both thermal and subsequent resulted remaining stress environments in dissimilar friction stir welding of AA6061-T6 and AA2024-T3 alloys. The thermal analysis step was conducted first and followed by a mechanical analysis step in whi

This article uses coupled Eulerian–Lagrangian finite element algorithm to conduct a three-dimensional thermomechanical study to capture the shape and characteristics of defect type generated while achieving the dissimilar friction stir welding of aluminium alloys. The volume-of-fluid method is used to model the Eulerian region and predict the localised formation of process defects. Three different tool shapes are utilised to achieve the dissimilar friction stir welding joining between AA 2024-T3 on the advancing side and AA 6061-T6 on the retreating side. Process parameter effects such as rotational tool speed, traverse tool speed and tool tilt angle are also investigated. The finite element model results are validated by comparing with t

T-joints are common structures encountered in the assemblage of many industrial applications due to their advantages. However, joining these structures when using Friction Stir Welding (FSW) could be prone to defects that cause severe consequences like loss of strength and fracture. The current paper implements an experimental procedure to assess the effect of geometrical tool shape on void formation in friction stir welded AA 6061-T6 T-joint configuration. Taguchi optimization method was put into service to minimize the number of experiments and fulfil the goal of discovering the optimal FSW parameters that allow the manufacturing of such configurations with high mechanical properties. X-ray radiography and micrograph images were u

This research deals with the effects of welding variables using MIG/MAG spot by using Argon (Ar) gas and CO₂ to show their effect on the mechanical characteristics and microstructure of low alloy steel type DIN15Mo3 and determine the optimum condition for the process of welding ; current & time. The results show the possibility of using CO₂ and also Ar in low alloy steel welding with a little decrease in the shear force of not more than 13% for 4mm thickness and time 2sec. The shear force increased when using Ar instead of CO₂ to be , The shear force reach 36KN when using Ar at 2mm thickness  time of 8 sec and current of 220 Amp. , when used CO₂ instead of Ar d

A new tool geometry was used to achieve friction stir spot welding (FSSW) in which the shoulder was designed separately from the rotating pin, and in order to examine weldment strength through the modified tool, a lap joints of AA2024 aluminum alloy plate 1 mm thick were welded successfully by using 6 mm pin diameter and varying process parameters (rotational speeds, tool nose geometry, and depth of tool penetration in the lower welded plate). Experimental tests indicate that the maximum average tensile shear load was 3100 N at the best selected condition. Microstructure examination and micro hardness test along the spot zones were investigated as well as measuring pin penetration load. Visual inspection of the welded spot surface shows a g

The aim of present study is to determine the optimum parameters of friction stir welding process and known the most important parameter along with percentage contribution of each parameter which effect on tensile strength and joint efficiency of FS welded joint of  dissimilar aluminum alloys AA2024-T3 and AA7075-T73 of 3 mm thick plates by applied specific number of experiments using Taguchi method .AA2024 was placed on the advancing side and AA7075 on the retreating side. FSW was achieved under three different rotation speeds (898, 1200 and 1710) rpm, three different welding speeds (20, 45 and 69) mm\min , three different pin profiles (cylindrical, threaded cylindrical and cone) and tool tilt angle 2^◦. Taguchi method w