FE Modelling of Mechanical Tensioning for Controlling Residual Stresses in Friction Stir Welds

David Richards, Philip Prangnell, Philip Withers, S.W. Williams, A. Wescott, E.C Oliver

    Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

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    Abstract

    Although Friction Stir Welding (FSW) avoids many of the problems encountered whenfusion welding high strength Al-alloys, it can still result in substantial residual stresses that have a detrimental impact on service life. An FE model has been developed to investigate the effectives of the mechanical tensioning technique for controlling residual stresses in FSWs. The model purely considered the heat input and the mechanical effects of the tool were ignored. Variables, such as tensioning level, heat input, and plate geometry, have been studied. Good general agreement was found between modelling results and residual stress measurements, justifying the assumption that the stress development is dominated by the thermal field. The results showed a progressive decrease in the residual stresses for increasing tensioning levels and, although affected by the heat input, a relatively low sensitivity to the welding variables. At tensioning levels greater than ~ 50% of the room temperature yield stress, tensile were replaced by compressive residual stresses within the weld.
    Original languageEnglish
    Title of host publication6th Int. Friction Stir Welding Symposium
    Subtitle of host publication Canada
    Place of PublicationUK
    PublisherThe Welding Institute
    Publication statusPublished - 2006
    Event6th Int. Friction Stir Welding Symposium - St Sauveur, Canada on 10-13 October 2006, Canada
    Duration: 10 Oct 200613 Oct 2006

    Conference

    Conference6th Int. Friction Stir Welding Symposium
    Country/TerritoryCanada
    CitySt Sauveur, Canada on 10-13 October 2006
    Period10/10/0613/10/06

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