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Development and analysis of ultrasonic assisted friction stir welding process.

机译：超声辅助摩擦搅拌焊接工艺的发展与分析。

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摘要

Friction stir welding (FSW) has been successfully used for joining low melting temperature materials. However, applications in high strength alloys, such as titanium and stainless steel, remain limited due to large welding force and consequent tool wear. Ultrasonic-assisted processes have been coupled with tooling in various manufacturing processes in order to enhance the performance of conventional machining and bonding processes. We suggest ultrasonic assisted friction stir welding (UaFSW), as a hybrid system, in order to improve the weld quality and welding efficiency of high melting temperature materials.;For successful and effective implementation of the UaFSW process, integration of the ultrasonics on the FSW equipment is necessary, while minimizing vibratory effects on the remaining machine assembly. The UaFSW system is being developed and its mechanism needs to be understood using both the experiments and the numerical simulations. FE simulations of the UaFSW using ABAQUS are carried out to examine plunge forces and temperature profiles during the plunge stage of the process. To gain the fundamental understanding and insights of the process, force and temperature measurement, mechanical testing, and defect analysis are used in studying the influence of the ultrasonic oscillations on the conventional FSW system.;Taking advantage of the characteristics of ultrasonic vibration, the UaFSW of aluminum alloy enables us to decrease the welding force and enhance mechanical properties of welded part in terms of elongation and yield strength. It was shown that ultrasonic integration on FSW tool helps to decrease the chance of formation of welding defect. It could be also observed from the experimental results that ultrasonic vibration helps to decrease the welding forces for welding of high melting temperature material. Force reduction of 6% during the peak region and 12.5% during the welding one was observed. For FE analysis of UaFSW, it was predicted that the plunge forces were reduced by using the ultrasonic vibrations. In addition, it was shown that the plunge forces could be decreased by increasing the amplitude of vibrations.
机译：搅拌摩擦焊（FSW）已成功用于连接低熔点材料。然而，由于高的焊接力和随之而来的工具磨损，在高强度合金如钛和不锈钢中的应用仍然受到限制。超声辅助工艺已与各种制造工艺中的工具相结合，以增强常规机加工和粘合工艺的性能。我们建议将超声辅助摩擦搅拌焊接（UaFSW）作为混合系统，以提高高熔点温度材料的焊接质量和焊接效率。;为了成功有效地实施UaFSW工艺，请将超声与FSW集成设备是必需的，同时最大程度地减少了对其余机器组件的振动影响。 UaFSW系统正在开发中，需要通过实验和数值模拟来了解其机理。使用ABAQUS对UaFSW进行了有限元模拟，以检查过程的突入阶段的突入力和温度曲线。为了获得对过程的基本理解和见识，力和温度的测量，机械测试和缺陷分析被用于研究超声振荡对常规FSW系统的影响。;利用超声振动的特性，UaFSW铝合金材料使我们能够降低焊接力，并在延伸率和屈服强度方面提高焊接零件的机械性能。结果表明，在FSW工具上进行超声集成有助于减少焊接缺陷形成的机会。从实验结果还可以观察到，超声振动有助于降低用于焊接高熔点材料的焊接力。观察到在峰值区域力降低了6％，在焊接过程中力降低了12.5％。对于UaFSW的有限元分析，可以预见的是，通过使用超声振动，可以减小插入力。另外，已经表明，可以通过增加振动幅度来减小切入力。

著录项

  • 作者

    Park, Kwanghyun.;

  • 作者单位

    University of Michigan.;

  • 授予单位 University of Michigan.;
  • 学科 Engineering Mechanical.
  • 学位 Ph.D.
  • 年度 2009
  • 页码 111 p.
  • 总页数 111
  • 原文格式 PDF
  • 正文语种 eng
  • 中图分类
  • 关键词

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