Procedia Materials Science 5 ( 2014 ) 630 639

Available online at www.sciencedirect.com

2211-8128 2014 Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of Organizing Committee of AMME 2014
doi: 10.1016/j.mspro.2014.07.309
ScienceDirect
International ConIerence on Advances in ManuIacturing and Materials Engineering,
AMME 2014
Time EIIicient Simulations oI Plunge and Dwell Phase oI FSW and
its SigniIicance in FSSW
Vinayak Malik
a,
*, Sanjeev N.K
b
, H. Suresh Hebbar
b
, Satish V. Kailas
a
a
Department of Mechanical Engineering, Inaian Institute of Science, Bangalore 560012, Inaia
b
Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, Mangalore 575025, Inaia
Abstract
Friction Stir Spot Welding (FSSW) is gathering attention oI automotive and aerospace sectors. It is an alternative Ior rivets,
electric resistance welding and oIIers substantial advantages with regard to energy consumption, environmental protection and
mechanical properties oI weld. At present, research eIIorts are being made to gain a better understanding oI the process, to
explore diIIerent tool conIigurations, to optimize the set oI process parameters and to widen the applicability oI FSSW. In this
regard, having reliable Iinite element model that is capable oI simulating FSSW with minimal possible simulation time can turn
out handy to reduce the number oI physical experiments required in such studies and applications. The current work investigates
the plunge and dwell phase oI Friction Stir Welding (FSW) using three-dimensional (3-D) Iinite element (FE) modelling. A 3-D
FE model is developed in the commercial code ABAQUS/Explicit using the Coupled Eulerian-Lagrangian Formulation, the
Johnson-Cook material law, and Coulomb`s Law oI Iriction. A successIul weld depends on proper material Ilow and temperature
existing during the process. This is dictated by selected processing parameters. II the appropriate conditions are not present, cold
or hot deIects occur, leading to a Iaulty weld. Since FSSW comprises oI plunge and dwell phase, the simulation results are
explained in the context oI modeling oI FSSW. The simulation results include eIIect oI process parameters (tool rotation speed,
plunge velocity, plunge depth) and tool geometry (pin proIile) on estimating temperature and morphology oI weld region. Tools
with square and triangular pin proIile aided in increasing the process temperature and widening the weld nugget with less power
consumption compared to their counterpart. Simulation time reduced to a greater extent in CEL when compared to Lagrangian,
Eulerian and ALE.
2014 The Authors. Published by Elsevier Ltd.
Selection and peer-review under responsibility oI Organizing Committee oI AMME 2014.
Keyworas.FSW; Plunge and dwell phase; FSSW; FEM; Coupled Eulerian-Lagrangian
* Corresponding author. Tel.: 91-988-640-6375.
E-mail aaaress. vinayakmalik008gmail.com, vinayakmecheng.iisc.ernet.in
2014 Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of Organizing Committee of AMME 2014
631 Vinayak Malik et al. / Procedia Materials Science 5 ( 2014 ) 630 639
Nomenclature
A Yield stress B Body Iorce
C Strain rate Iactor CEL Coupled Eulerian-Lagrangian
ERSW Electrical resistance spot welding FBJ Friction bit joining
FEM Finite Element Method FFSW Filling Iriction stir welding
HAZ Heat aIIected zone HDS Hardened steel
m Temperature exponent n Strain exponent
NT Nodal temperature PEEQ Plastic strain
RFSSW ReIill Iriction stir spot welding rpm Revolution per Minute
SZ Stir zone TMAZ Thermo-mechanically aIIected zone
melt
T Melting point or solidus temperature
room
T Room or ambient temperature
T EIIective temperature o
y
Flow stress
c
p
/ c
0
Plastic strain 3-D Three dimensional
1. Introduction
Friction stir welding (FSW) was invented at The Welding Institute (TWI) oI the United Kingdom (Cambridge) in
1991 as a solid-state joining technique, occurring below the solidus temperature oI the metals being joined and was
initially applied to aluminum alloys. Since then FSW has rapidly evolved and has opened up a variety oI research
channels. It is being touted as the most signiIicant development in metal joining in the last decade.
Fig. 1. Basic principle oI the FSW process.
The basic concept oI FSW is that, the two metals to be welded together are held in place against a backing plate
using a clamping system. The rotating tool is then slowly plunged with a downward Iorce into the weld joint. It
dwells Ior a Iew seconds aiding generation oI Irictional heat. This leads to plasticization and Ilow oI material in tool
vicinity. Once this point is reached, the tool is traversed along the joint Iorming the weld behind the tool as it moves
along (R.S. Mishra and Ma, 2005; Mishra and Mahoney, 2007). The Fig. 1 shows the schematic representation oI
Iriction stir welding process (Kumar et al., 2009). The main beneIit oI Iriction stir welding is that the base material
is joined below its melting point.
It is important to understand the temperature distribution, strain and strain rate development. In FSW, heat is
generated primarily on the basis oI Iriction at tool/work-piece interIace and plastic deIormation oI work material.
The amount oI heat conducted into the work-piece dictates a successIul process which is deIined by the weld
quality, microstructure as well as the residual stress and distortion oI the work-piece. Plunging is the initial stage oI
the FSW process and it plays a vital role in Iormation oI weld, as it creates the initial thermo-mechanical conditions
in the work material which are required prior to start oI the linear welding phase (Veljic et al., 2013). Hence
understanding dissipation and distribution oI heat Ior obtaining temperature proIiles and stress Iields are remarkably
signiIicant in getting an insight oI FSW process. FE modeling oI plunge phase is very demanding since, it resembles
FSSW process. FSSW was developed in 2001 to replace resistance spot welding Ior aluminium sheets, which is one
632 Vinayak Malik et al. / Procedia Materials Science 5 ( 2014 ) 630 639
oI the main variant oI FSW (Hancock, 2004). FSSW is mainly applied in lap joint conIigurations with three phases;
plunging, stirring or dwell and retracting as shown in Fig. 2 (Lin et al., 2008; Pouranvari and Marashi, 2013).
Fig. 2. Basic principle oI the FSSW process.
FSSW is a solid-state welding process in which a specially designed rotating cylindrical tool with varying end
geometry and pin is Iirst plunged into the sheets, while the backing plate beneath the lower sheet supports the
downward Iorce (Pouranvari and Marashi, 2013).The downward Iorce and the rotational speed are maintained Ior an
appropriate time to generate Irictional heat. Then, heated and soItened material adjacent to the tool deIorms
plastically, and a solid-state bond is made between the surIaces oI the upper and lower sheet. Finally, the tool is
drawn out oI the sheets and protruded pin leaves a characteristic exit hole in the middle oI the joint (Fanelli et al.,
2012).
There are numerous applications Ior FSSW, especially in the transportation industry, employing aluminium
structures. Any application that is currently riveted, toggle-locked or spot welded can oIten have FSSW substituted
with little eIIort and changes. Challenges with electrical resistance spot welding (ERSW) includes the need to
chemically clean the aluminium alloys within 8 hours oI joining, excessive electrode mushrooming causing poor
welds to be made, process variability and shunting problems which require greater spacing oI the welds and its
application is limited to 0.25 - 4 mm. Challenges with the mechanical rivets include high cost Ior Iasteners,
potentially higher down time due to Ieeding issues and need Ior other operations Ior non-selI-piercing rivets.
Processes such as toggle-lock are simple and cheap but have less strength than ERSW. FSSW is not saddled with the
problems that are cited above due to the unique nature oI the process (Smith et al., 2004). Higher plastic deIormation
is obtained in the welding zone oI the FSSW process than the resistance spot welding (RSW) process. The hardness
increase in the FSSW process is higher than in the RSW process. Also the tensile shear strengths oI the FSSW
welded joints are higher than those oI the resistance spot welded joints (Kulekci et al., 2011). The speed oI the
process is competitive with ERSW but it is much more consistent because FSSW is not as sensitive to changing
material conditions and surIace conditions (Smith et al., 2004). One oI the drawbacks oI FSSW is remainder oI exit
hole at end oI the operation.However, recent advancement shows the introduction and development oI variety oI
methods and approaches in Iilling oI keyhole (Mishra and Mahoney, 2007; Uematsu et al., 2008; Huang et al., 2011;
Han et al., 2013; Shen et al., 2013a) like Iilling Iriction stir welding (FFSW), reIill Iriction stir spot welding
(RFSSW), Iriction bit joining (FBJ). The Iilling oI key hole can be perIormed through the any techniques and tools
as shown in Fig. 3 (Mishra and Mahoney, 2007; Shen et al., 2013a; Huang et al., 2011).
Fig. 3. (i) Schematic illustration oI the RFSSW processes; (ii) Joint and corresponding tool
with diIIerent processes, (a) keyhole leIt by FSW, b) aIter FFSW, c) aIter FSP.
The schematic illustration oI the Iriction stir spot welding process with reIilling is shown in Fig. 3. RFSSW is
perIormed using a tool assembly comprised oI three parts: clamping ring, sleeve and pin. Furthermore, the three
633 Vinayak Malik et al. / Procedia Materials Science 5 ( 2014 ) 630 639
components oI the tool are operated by three separate actuators so that they are mounted coaxially and can be rotated
and moved up and down independently oI each another. Prior to welding, the clamping moves the entire welding
head against the work pieces to keep the sheets to be welded tightly secured during the welding process and to avoid
plasticized material to be lost in the Iorm oI Ilash (Rosendo et al., 2011; Shen et al., 2013a; Shen et al., 2013b).
Fig. 3 (ii) shows the joint and the corresponding tool with diIIerent processes. During the FFSW process, the
consumable bit oI the aluminum alloy along with steel shoulder is plunged into the keyhole leIt at the end oI the
FSW joint. The heat generated by Iriction at the shoulder and the joining bit surIace soItens the material oI keyhole
wall and bit. The shoulder provides a Iorging Iorce which helps in joining oI this plasticized section. FSP Iollows
thereaIter; where a non-consumable tool consisting oI a shoulder without protruding pin provides mechanical
mixing and plastic deIormation (Huang et al., 2011).
At present, research eIIorts are being made to gain a better understanding oI the process, to explore diIIerent tool
conIigurations, to optimize the set oI process parameters and to widen the applicability oI FSSW. The simulation
results include eIIect oI process parameters (tool rotation speed, plunge velocity, plunge depth) and tool geometry
(pin proIile) on estimating Iorces on tool essential Ior tool design, temperature, strain and strain rate distribution in
weld region. Other main objective oI the current work is to explore Coupled Eulerian Lagrangian technique with
simulation time in mind, to make Iinite element simulations oI FSW and its variants time eIIicient.
2. Model description
FE model is developed in the commercial code ABAQUS/Explicit using the Coupled Eulerian-Lagrangian
Formulation, the Johnson-Cook material law, and Coulomb`s Law oI Iriction. In this section the tool and work-piece
geometries considered and description to Coupled Eulerian-Lagrangian Formulation, the Johnson-Cook material
law, and Iriction coeIIicients are given.
2.1. Tool Geometry ana Work-piece
Fig. 4. Geometry oI tool employed.
The tool dimensions are 25mm shoulder dia., Irustum shaped pin with 6/4 diameter at base and tip, pin length is
4.7 mm. Material oI tool is HDS. The Fig. 4 shows the geometry oI tool. The work-piece oI 100X100 mm area and
thickness oI 5 mm is considered in simulation. The Eulerian domain is meshed with multi-material thermally
coupled 8-node (EC3D8RT) Eulerian elements and the void region thickness is taken as 1 mm.
2.2. Couplea Eulerian-Lagrangian Formulation
The coupled Eulerian-Lagrangian (CEL) method attempts to capture the strengths oI Lagrangian and Eulerian
methods. In general, a Lagrangian reIerence Irame is used to discretize the Tool while an Eulerian Irame is used to
discretize the Work-piece (Brown et al., 2002; D.J, 1992; Muci-Kchler et al., 2010; Documentation, 2012). The
634 Vinayak Malik et al. / Procedia Materials Science 5 ( 2014 ) 630 639
boundary oI the Lagrangian domain is typically taken to represent the actual interIace between the tool and the
work-piece. The great advantage oI CEL approach is that all problems associated with mesh distortion are
eliminated as the Eulerian description allows Iinite elements to be Iixed in space and the material to Ilow through
these elements. This Iact enables application in numerical simulation oI problems involving severe material
deIormation as it takes place during body impacts. The impacting Iorces are transIerred to the Lagrangian structure
through Eulerian-Lagrangian contact which is based on the penalty contact algorithm.
2.3. Johnson-Cook elasticplastic moael
Johnson and Cook (1983), presented a constitutive model in which the Ilow stress is calculated as a Iunction oI
temperature and strain rate up to the melting point or solidus temperature, which is given by
( )
1 1
m
n
p
room
y p
o melt room
T T
A B C
T T

(
( | | | |
(
( = + +
( | |
(


( ( \ . \ .

( 1 )
Where
melt
T - 502
0
C is the melting point or solidus temperature,
room
T - 25
0
C the ambient temperature, T the
eIIective temperature, A- 369 MPa the yield stress, B- 684 MPa the strain Iactor, n- 0.73 the strain exponent, m- 1.7
the temperature exponent, c
p
/ c
0
the plastic strain and C- 0.0083 the strain rate Iactor. A, B, C, n, and m are
material/test constants Ior the Johnson-Cook strain rate dependent yield stress. The Material properties oI AA2024-
T3, considered Ior simulations are as per the values taken by Veljic et al. (2013).
2.4. Friction Coefficient
The Iriction coeIIicient between tool and work-piece is an input parameter in FE model and used in heat
generation Iormulations. A variety oI Iriction coeIIicient values have been Iound in literature with the majority oI
them being a constant value. Tutunchilar et al. (2012), used Iriction coeIIicient oI 0.4, 0.5, and 0.6, under 100
mm/min transverse speed and 900 rpm rotational speed. BuIIa et al. (2009), also used a constant Iriction Iactor oI
0.46 between work-piece and tool. It was Iound that using hybrid model and Iriction coeIIicient oI 0.7 gave best
results in view oI temperatures. Hybrid Iriction model uses together both Coulomb and shear Iriction models. These
models were selected due to the very complex process oI FSW (KadirGk and Aydin, 2013). Also according to
investigations Irom Kumar et al. (2009), the coeIIicient oI Iriction and temperatures do have a synergic inIluence on
each other. The coeIIicient oI Iriction in the FSW condition was Iound to be as high as 1.2 to 1.4 at 400
0
C to 450
0
C.
ThereIore, in present simulations a Iriction coeIIicient oI 1 is considered Ior all simulation conditions.
3. Results and discussion
Initial model is developed reIerring to experiments oI plunge and dwell phase Ior aluminium 2024 alloy.
Comparison is made with simulated results Ior (i) simulation time (ii) temperature response (iii) shape and size oI
weld zones (iv) capability oI predicting deIects and (v) selection oI appropriate tools. For experimental results, weld
zones are cross checked Irom macrographs and temperatures are traced with the help oI thermocouples. Further
validation oI model was carried out using temperature results and macrographs published by Merzoug et al. (2010)
and Hirasawa et al. (2010). Here the results are categorized and discussed under sub sections Ior materials AA2024
and AA6061.
3.1. Comparison of simulation time
The comparison oI simulation time is done basically using the data available in the literature. In the past FE
Modeling oI FSW is perIormed using either Eulerian, Lagrangian or Arbitrary Lagrangian Eulerian (ALE)
Iormulations. The time taken Ior simulation as stated by Lasley (2005) is 42 days to run 5.44 seconds using
supercomputing Iacility and as stated Irom Awang (2007), it is 14 days and 12 hours on a 3.60 GHz Intel Pentium 4
635 Vinayak Malik et al. / Procedia Materials Science 5 ( 2014 ) 630 639
processor Ior the simulation time oI 1.505 seconds.With Iurther advancements in FE packages there was as a little
reduction in computational time. As stated Irom Assidi et al., (2010), it is 12 days 20 hours with ALE Iormulation
and 6 days 14 hours with Eulerian Iormulation. But in present work, with the use oI CEL the time taken Ior
simulation is greatly reduced and also the high distortion and convergence problems associated with Lagrangian and
ALE Iormulations are overcome. The Table 1shows the time taken with respect to diIIerent simulation conditions.
Table 1. Simulation conditions and time taken under CEL Iormulation.
Simulation conditions Time taken (With default processor settings)
Material: 2024 alloy, Plunge velocity: 10 mm/min, Dwell time: 10 sec,
Plunge distance: 4.9 mm, Total Iield output intervals: 15
3.5 hours with core 2 duo processor,
2.5 hours with i7 processor
Material: 6061 alloy, Plunge velocity: 20 mm/min, Plunge distance: 3.7 mm,
Dwell time: 2 sec, Total Iield output intervals: 15
3 hours with core 2 duo processor,
1.75 hours with i7 processor
Material: 2024 alloy, Plunge velocity: 10 mm/min, Plunge distance: 4.9 mm,
Dwell time: 10 sec, Weld distance: 60 mm, Weld velocity: 60 mm/min,
Total Iield output intervals: 15
9.5 hours with core 2 duo processor,
4.5 hours with i7 processor
3.2. Temperature response
Plunge trials Ior temperature measurements were carried on AA2024-T3 (5 mm thick plate) with plunge
velocity oI 10 mm/min, 0
0
tilt and 0.2 mm plunge depth. Three trials were carried Ior tool rotational speeds oI 350
rpm, 950 rpm and 1550 rpm each. The plunge and dwell phase was approximately oI 30 and 10 seconds
respectively. To measure the temperature change during experiments, thermocouples were employed. The mounting
oI thermocouples and the region in which the nodes are selected in simulations correspond to similar locations oI
thermocouples as illustrated in Fig. 5. During plunge, gradual increase in temperature was observed Ior 350 rpm
unlike 950 and 1550 rpm. It is observed that temperature reaches a steady state in dwell phase oI the weld as shown
in graphs (see Fig.7). This points to the Iact that temperature has linear relation with plunge depth; it increases with
increase in plunge depth and vice-versa. For a given plunge depth there is a certain maximum temperature that can
be obtained and once it is achieved it remains the same in dwell phase too. The Table 2 shows the close-up view oI
temperature proIile aIter plunge and dwell phase on the top sheet. LeIt column shows the images Irom experiments
and right column exhibits simulation images with predicted temperature.
Fig. 5. Location oI thermocouples in experiment and simulation.
Fig. 6. Comparison oI simulated micro structural zones with experimental results Ior FSSW.
636 Vinayak Malik et al. / Procedia Materials Science 5 ( 2014 ) 630 639
Fig.7. Temperature proIile Irom plunge experiments measured at diIIerent tool rotational speeds Ior AA2024;
(a) At 350rpm, (b) At 950rpm and (c) At 1550rpm.
Table 2. Close-up view oI the Iriction stir weld aIter plunge and dwell phase (on the top sheet).
Experimental Simulation
350rpm
950rpm
1550rpm
637 Vinayak Malik et al. / Procedia Materials Science 5 ( 2014 ) 630 639
The simulated result closely resembles macrograph as observed in experimental trial shown in Fig. 6 (Hirasawa
et al., 2010). This helps in predicting the shape and size oI weld nugget a priory to experiments Ior given process
conditions. Thus, this modelling technique sheds some light on the complex material Ilow and mixing phenomena
during FSSW. Table 3 Iurther endorses the ability oI weld nugget predictions using equivalent plastic strain option.
Table 3. Comparison oI simulated results highlighting equivalent plastic strain with experimental macrographs Ior plunge carried on
AA2024 (5 mm thick plate).
Experimental Simulation
350rpm
950rpm
1550rpm
3.3. Effect of low rpm
Here deliberately low tool rotation speed oI 100 rpm was tried Ior a plunge velocity oI 10 mm/min, displacement
oI 4.9 mm i.e. 0.2 mm plunge depth. This was done to test the capability oI CEL to predict deIect Iormation
resulting Irom improper Ilow oI material. The Fig.8 shows the incomplete movement oI material around the tool
resulting in possible deIect Iormation. It also gives inIormation on various micro structural regions (like nugget
zone, thermo mechanically aIIected zone, heat aIIected and unaIIected zone) related to its morphology (size and
shape) in response to the chosen process conditions.
Fig.8. Incomplete movement oI material around the tool resulting in possible deIect Iormation.
3.4. Effect of tool configuration on temperature
Investigations were carried Ior changing tool conIigurations to study its eIIect on temperature generated and
evolution oI weld nugget during the process. The trials listed in the Table 4 were carried on AA6061 (2 plates oI 2
mm each) with a tool rotation speed oI 2000 rpm, plunge velocity oI 20 mm/min and plunge depth oI 0.2 mm (with
pin length oI 2.8 mm). It is observed that as the swept diameter increases the temperature and nugget area increases
Ior same rotational speed, plunge velocity and plunge depth. As shown in the Table 4 square tool aids in increasing
the temperature and weld nugget size compared to its counter parts. The working temperatures in FSW are around
0.8-0.9
melt
T (Qian et al., 2013). However, Ior the current case the selected process parameters results in higher
temperatures Ior a square and rectangular tool conIiguration. This helps in wisely choosing the tool wherein we get
the required temperature and weld nugget size Ior the least power consumption.
638 Vinayak Malik et al. / Procedia Materials Science 5 ( 2014 ) 630 639
Table 4. Temperature proIile with respect to diIIerent tool conIigurations.
Tool
configuration
Tool drawing
Swept
dia,
of pin
Temperature
Square Tool 4.24
Rectangular Tool 4.03
Triangular Tool 4
Circular Tool
(Outside taper)
3
4. Conclusions
Based on the current investigation and the results obtained, Iollowing are the key Iindings:
(i) CEL method helps in reducing simulation time to a larger extent there by making FE simulations oI
FSW and its variants time eIIicient.
(ii) The proposed method helps in wise selection oI tools wherein we get the desired weld nugget
morphology and working temperature with minimum possible power consumption.
(iii) CEL method exhibits the potential oI deIect prediction Ior given process conditions which ultimately
help in selecting the appropriate process parameters.
(iv) The proposed method presents the strong possibility oI widening the eIIective optimization study on
FSW and its variants.
Acknowledgements
The authors would like to thank Department oI Mechanical Engineering, Indian Institute oI Science, Bangalore
Ior providing research Iacilities.
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