This study focuses on developing a computational thermo-mechanical model and analyzing the dual-rotational friction stir welding (DR-FSW) technique for joining AA6061-T6. DR-FSW, a variation of FSW, the shoulder and the pin operate independently as separate components and may be modified to meet various welding requirements. This paper introduces a numerical model of DR-FSW utilizing the advanced meshless Smoothed Particle Hydrodynamics (SPH) technique. The model replicates a published and validated FSW model, which predicts the thermal cycles with an accuracy of 1.2% on the advancing side (AS) and 2.3% on the retreating side (RS). A reduction in temperatures in the shoulder-affected zone (SAZ) can be observed while allowing for adequate material flow and material mixing in the pin-affected zone (PAZ). Future recommendations are proposed, such as the more extensive study of process parameters, particularly change in plunge depths (PDs) of the pin and variable rotational speeds (RSs) of the shoulder and pin.

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Computational Modelling and Analysis of Dual-Rotational Friction Stir Welding: Using Advanced Meshless SPH Method

  • Venkata Somi Reddy Janga,
  • Nabihah Sallih,
  • Mokhtar Awang,
  • Tamiru Alemu Lemma

摘要

This study focuses on developing a computational thermo-mechanical model and analyzing the dual-rotational friction stir welding (DR-FSW) technique for joining AA6061-T6. DR-FSW, a variation of FSW, the shoulder and the pin operate independently as separate components and may be modified to meet various welding requirements. This paper introduces a numerical model of DR-FSW utilizing the advanced meshless Smoothed Particle Hydrodynamics (SPH) technique. The model replicates a published and validated FSW model, which predicts the thermal cycles with an accuracy of 1.2% on the advancing side (AS) and 2.3% on the retreating side (RS). A reduction in temperatures in the shoulder-affected zone (SAZ) can be observed while allowing for adequate material flow and material mixing in the pin-affected zone (PAZ). Future recommendations are proposed, such as the more extensive study of process parameters, particularly change in plunge depths (PDs) of the pin and variable rotational speeds (RSs) of the shoulder and pin.