TY - JOUR
T1 - Parametric investigation of friction stir welding of aluminum alloy and Inconel 718 using finite element analysis
AU - Abotaleb, Ahmed
AU - Khraisheh, Marwan
AU - Remond, Yves
AU - Ahzi, Said
N1 - Publisher Copyright:
© The Author(s) 2024.
PY - 2024/12
Y1 - 2024/12
N2 - Friction Stir Welding (FSW) has emerged as a prominent technique for joining metallic materials, offering advantages in both similar and dissimilar material combinations. Despite its effectiveness, further advancements are needed to address industry demands and enhance the understanding of the FSW process. Welding nickel-based superalloys like Inconel 718 poses specific challenges, with existing literature suggesting that achieving successful welds requires high axial forces and precise process parameters, limiting its practical application in industries. To tackle these issues, this research proposes the utilization of 3D finite element models integrating multiphysics aspects, encompassing material flow and heat transfer mechanisms such as conduction, convection, and radiation. These models were validated against existing experimental data and employed to analyze temperature and strain distributions within the heat affected zone and weld nugget. The findings offer insights into the impact of various process parameters, including rotational speed, welding speed, normal force, cooling rate, and the effect of induction preheating, on key performance metrics like temperature profiles, grain size distribution, microhardness, and stress evolution. The outcomes underscore a notable correlation between process variables and performance indicators, facilitating a comprehensive understanding of the FSW process dynamics.
AB - Friction Stir Welding (FSW) has emerged as a prominent technique for joining metallic materials, offering advantages in both similar and dissimilar material combinations. Despite its effectiveness, further advancements are needed to address industry demands and enhance the understanding of the FSW process. Welding nickel-based superalloys like Inconel 718 poses specific challenges, with existing literature suggesting that achieving successful welds requires high axial forces and precise process parameters, limiting its practical application in industries. To tackle these issues, this research proposes the utilization of 3D finite element models integrating multiphysics aspects, encompassing material flow and heat transfer mechanisms such as conduction, convection, and radiation. These models were validated against existing experimental data and employed to analyze temperature and strain distributions within the heat affected zone and weld nugget. The findings offer insights into the impact of various process parameters, including rotational speed, welding speed, normal force, cooling rate, and the effect of induction preheating, on key performance metrics like temperature profiles, grain size distribution, microhardness, and stress evolution. The outcomes underscore a notable correlation between process variables and performance indicators, facilitating a comprehensive understanding of the FSW process dynamics.
KW - COMSOL multiphysics
KW - Finite element analysis
KW - Friction Stir Welding
KW - Inconel 718
KW - Parametric analysis
UR - http://www.scopus.com/inward/record.url?scp=85209742585&partnerID=8YFLogxK
U2 - 10.1007/s44245-024-00076-1
DO - 10.1007/s44245-024-00076-1
M3 - Article
AN - SCOPUS:85209742585
SN - 2731-6564
VL - 3
JO - Discover Mechanical Engineering
JF - Discover Mechanical Engineering
IS - 1
M1 - 37
ER -