D.H. Lammlein PhD Dissertation - Vanderbilt University

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[25] The application of shoulderless conical tools in friction stir welding: An experimental and theoretical study; D H <strong>Lammlein</strong>, D R DeLapp; Mat. And Design, Volume 30, Issue 10, 4012-4022, Dec 2009 [26] Torque control of friction stir welding for manufacturing and automation; W R Longhurst, A M Strauss, G E Cook, P A Fleming; International Journal of Advanced Manufacturing Technology; .Submitted June 17, 2009 and under review. [27] Experimental investigation of the influence of the FSW plunge processing parameters on the maximum generated force and torque; S Zimmer, L Langlois, J Laye, R Bigot; Int J Adv Manuf Technol, July 2009 [28] Introduction to Robotics: Mechanics and Control (3rd Edition); J J Craig [29] Determination of flow stress: Part 1 constitutive equation for aluminum alloys at elevated temperatures.; T Sheppard, D Wright; Met Technol 1979, Jun 6, 215–23 [30] Hot workability; C M Sellars, W J M Tegar; Int Metall Rev 1972; 17:1–24 [31] Torque based weld power model for friction stir welding J W Pew, T W Nelson, C D Sorensen; Sci Technol Weld Join 2007;12(4):341 152
CHAPTER V FRICTION STIR WELDING OF SMALL DIAMETER PIPE: AN EXPERIMENTAL AND NUMERICAL PROOF OF CONCEPT FOR AUTOMATION AND MANUFACTURING D.H. <strong>Lammlein</strong>, B. T. Gibson, D. R. DeLapp, C. Cox, A. M. Strauss, G. E. Cook. Friction Stir Welding of Small Diameter Pipe: An Experimental and Numerical Proof of Concept for Automation and Manufacturing. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Submitted July 15, 2010. Abstract Friction stir welding (FSW) is a powerful joining process which is limited by its range of application and processing rate. Here the range of application is extended to small diameter butted pipe sections and high processing rates are applied for increased productivity in manufacturing. Full penetration friction stir welds are performed on butted sections of aluminum alloy 6061-T6 pipe. These pipe sections are relatively small in diameter, 4.2 inches, and relatively thin walled, 0.2 inches. The small radius of curvature distinguishes this weld configuration geometrically from a butted plate configuration and presents unique challenges. This work confronts these challenges using experimental and numerical methods. A FSW process method producing acceptable pipe joints is demonstrated. Introduction Friction stir welding (FSW) is an effective and consistent materials joining technology which produces high strength and high integrity joints, particularly in aluminum alloys (Thomas, 1991). FSW is also attractive because it is a solid-state process, with temperatures not exceeding the melting point of the work material. Its use is limited primarily by the combined expense of the FSW machine itself and the lack of an operating knowledge base. However, superb joint quality and low continuing 153
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FRICTION STIR WELDING OF SPHERES, C
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TABLE OF CONTENTS TABLE OF FIGURES
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Appendix ..........................
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Figure 16: Left(FE streamline), Mid
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Figure 51: A thermal camera image t
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for a similar conventional weld (3/
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Figure 102: Tapered retraction proc
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setting are indicated. Note that st
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Unsupported welds of this kind with
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Figure 157: A thermal camera image
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ottom sample is a tungsten inert ga
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N - newton (force unit) n - visco-p
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INTRODUCTION Friction Stir Welding,
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educed conduction lengths. In small
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CHAPTER I LITERATURE REVIEW: COMPUT
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frictional condition at the interfa
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contact. The contact area can inclu
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For horizontal sections, a heat inp
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(1.11) where r p is the probe (pin)
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This efficiency term, η pd , is kn
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The heat input on the tool surface
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The added complication of these met
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Figure 5: Lateral cross sections of
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Flow stress in aluminum alloys is d
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Figure 8: Three flow fields a) rota
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and post-weld cool-down. This model
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Williams et al. [60] use a 2D-axisy
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Figure 16: Left(FE streamline), Mid
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Figure 18: Temperature contour over
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Figure 22: Temperature distribution
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Figure 24: Lateral velocity contour
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Figure 26: Experimental(white) vers
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Figure 28: Top view schematic of tu
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[5] Taylor RE, Groot H, Goerz T, Fe
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[41] Heinz B., Skrotzki B., Eggler
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CHAPTER II COMPUTATIONAL ANALYSIS O
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Figure 30: Blind t-joint setup with
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Figure 33: Process forces and later
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Figure 35: Experimental Welds, Axia
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Figure 37: FEA boundary conditions
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A 4500 N axial force is applied eve
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axial force with lateral offset dur
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Figure 42: Contour plot of von Mise
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Figure 44: Deformation contour for
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Figure 46: Quarter-plate model for
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Figure 49: Contour plot of deflecti
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where P is the weld power (W), Q is
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Figure 52: Fluent CFD model zones.
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Figure 55: Thermal contour of weld
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Figure 59: Thermal contour of weld
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Figure 61: Velocity vectors for 0.0
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Figure 65: Contour of velocity magn
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CHAPTER III THE APPLICATION OF SHOU
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Figure 66: A shoulder-less, conical
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Figure 68: Typical axial(Z-axis) fo
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Figure 71: 90° conical tool macros
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Figure 75: Run 3, 80° conical tool
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Figure 79: (90º tool) Ultimate ten
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Figure 83: (90º tool) Lateral forc
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Figure 87: (80º tool) Lateral forc
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The Eulerian, finite volume, CFD so
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Figure 92 shows the increasing elem
Page 125 and 126: Figure 91: CFD model geometry consi
Page 127 and 128: Figure 95: Lateral cross-section of
Page 129 and 130: Figure 96: Attempts a probe tapered
Page 131 and 132: CHAPTER IV THE FRICTION STIR WELDIN
Page 133 and 134: applications for its high strength
Page 135 and 136: Figure 97: Experimental weld sample
Page 137 and 138: Figure 99: Split protrusion type de
Page 139 and 140: with a cupped recess. It is however
Page 141 and 142: of tapered retraction (i.e. move th
Page 143 and 144: The adjustments in vertical positio
Page 145 and 146: manners the assigned depth was main
Page 147 and 148: Figure 108: Lateral macrosections f
Page 149 and 150: Figure 110: (Supported, cupped tool
Page 155 and 156: apparent strength of 26% parent whi
Page 157 and 158: with a 100º conical tool (0.025”
Page 159 and 160: Figure 119: Macrosection view of an
Page 161 and 162: and tooling. Torque is highly depen
Page 163 and 164: locally in proportion to the local
Page 165 and 166: Figure 126: (threaded tool) Contour
Page 167 and 168: Figure 128: (conical tool) Geometry
Page 169 and 170: Figure 131: (threaded tool) Lateral
Page 171 and 172: The results presented here show tha
Page 173 and 174: Figure 136:(from left: Tapered retr
Page 175: [8] Metallurgical analysis of ablat
Page 179 and 180: Collaboration between Advanced Meta
Page 181 and 182: eccentricity, the method of interio
Page 183 and 184: gas tungsten arc welding of small d
Page 185 and 186: Full penetration welds of 4.2” (1
Page 187 and 188: Figure 143: The curvature of the pi
Page 189 and 190: Figure 144: Experimental axial forc
Page 191 and 192: Together, a fine wall thickness tol
Page 193 and 194: Figure 147: Axial force history for
Page 195 and 196: The weld macrosections show complet
Page 197 and 198: Figure 154: Macrosections of welds
Page 199 and 200: Figure 157: A thermal camera image
Page 201 and 202: Figure 159: Average tool shank temp
Page 203 and 204: 471,146 faces. The meshes are fine
Page 205 and 206: Figure 162: A closeup view of mesh
Page 207 and 208: 4 2 3 4 5 16 " 1.745 2 0.24
Page 209 and 210: applied heat locally in proportion
Page 211 and 212: Figure 164: Modeled temperature con
Page 217 and 218: Figure 172: Model pathlines for the
Page 219 and 220: Figure 174: Model pathlines for the
Page 221 and 222: later speed setting, the tool welds
Page 223 and 224: Figure 178: Zoom view of a macro ta
Page 225 and 226: Figure 180: The superficial appeara
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Figure 182: The rotary welding appa
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Figure 185: A diagram illustrating
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CONCLUSION AND FUTURE WORK Conclusi
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new FSW process environment is reso
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D.H. Lammlein PhD Dissertation - Vanderbilt University

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