Thermomechanical deformation behaviour of DH36 steel during friction stir welding by experimental validation and modelling

Abstract

Friction stir welding is a solid state thermomechanical deformation process from which the plasticisation behaviour of the stirred material can be evaluated through the study of flow stress evolution. Flow stress data also supporting the development of a local microstructural numerical model have been generated. Hot compression testing of DH36 steel has been performed at a temperature range of 700–1100°C and strain rates from 10⁻³ to 10² s⁻¹ to study the alloy's thermomechanical deformation behaviour in conditions that simulate the actual friction stir welding process. It has been found that the evolution of flow stress is significantly affected by the test temperature and deformation rate. The material's constitutive equation and constants have been calculated after analysis of these data. Preliminary numerical analysis results are in good agreement with experimental observations.

Keywords

Friction stir welding Thermomechanical deformation Flow stress Low alloy steel Simulation Modelling

Get full access to this article

View all access options for this article.

References

Thomas

, Threadgill

and Nicholas

: ‘Feasibility of friction stir welding steel’, Sci. Technol. Weld. Join., 1999, 4, 365–372.

Nandan

, Debroy

and Bhadeshia

HKDH

: ‘Recent advances in friction-stir welding – process, weldment structure and properties’, Prog. Mater. Sci., 2008, 53, 980–1023.

Fonda

and Lambrakos

: ‘Analysis of friction stir welds using an inverse problem approach’, Sci. Technol. Weld. Join., 2002, 7, 177–181.

, Gu

and Ball

: ‘A review of numerical analysis of friction stir welding’, Prog. Mater. Sci., 2014, 65, 1–66.

Mishra

and Ma

: ‘Friction stir welding and processing’, Mater. Sci. Eng. R, 2005, R50, 1–78.

Reynolds

, Lockwood

and Seidel

: ‘Processing–property correlation in friction stir welds’, Mater. Sci. Forum., 2000, 331–337, 1719–1724.

Threadgill

, Leonard

, Shercliff

and Withers

: ‘Friction stir welding of aluminium alloys’, Int. Mater. Rev., 2009, 54, 49–93.

Lienert

, Stellwag

, Grimmett

and Warke

: ‘Friction stir welding studies on mild steel’, Weld. J. Res. Suppl., 2003, 1–9.

Reynolds

, Tang

, Posada

and Deloach

: ‘Friction stir welding of DH36 steel’, Sci. Technol. Weld. Join., 2003, 8, 455–460.

10.

McPherson

, Galloway

, Cater

and Hambling

: ‘Friction stir welding of thin DH36 steel plate’, Sci. Technol. Weld. Join., 2013, 18, 441–450.

11.

Toumpis

, Galloway

, Cater

and McPherson

: ‘Development of a process envelope for friction stir welding of DH36 steel – a step change’, Mater. Des., 2014, 62, 64–75.

12.

Nowotnik

: ‘Flow stress value and activation energy of hot deformed Inconel superalloys’, Adv. Manuf. Sci. Technol., 2008, 32, 51–62.

13.

Boisse

, Altan

and van Luttervelt

(Eds.): ‘Friction and flow stress in forming and cutting’; 2003, London, Kogan Page Science.

14.

Dieter

, Kuhn

and Semiatin

(Eds.): ‘Handbook of workability and process design’; 2003, Materials Park, OH, ASM International.

15.

Lin

, Chen

M.-S

and Zhong

: ‘Effect of temperature and strain rate on the compressive deformation behavior of 42CrMo steel’, J. Mater. Process. Technol., 2008, 205, 308–315.

16.

Zahedul

, Khandkar

and Khan

: ‘Thermal modeling of overlap friction stir welding for Al-alloys’, J. Mater. Process. Manuf. Sci., 2001, 10, 91–105.

17.

Simar

, Lecomte-Beckers

, Pardoen

and de Meester

: ‘Effect of boundary conditions and heat source distribution on temperature distribution in friction stir welding’, Sci. Technol. Weld. Join., 2006, 11, 170–177.

18.

Maniatty

, Liu

, Klaas

and Shephard

: ‘Stabilized finite element method for viscoplastic flow: formulation and a simple progressive solution strategy’, Comput. Methods Appl. Mech. Eng., 2001, 190, 4609–4625.

19.

Rajput

, Dikovits

, Chaudhari

, Poletti

, Warchomicka

, Pancholi

and Nath

: ‘Physical simulation of hot deformation and microstructural evolution of AISI 1016 steel using processing maps’, Mater. Sci. Eng. A, 2013, A587, 291–300.

20.

Abbasi

and Momeni

: ‘Hot working behavior of Fe–29Ni–17Co analyzed by mechanical testing and processing map’, Mater. Sci. Eng. A, 2012, A552, 330–335.

21.

Zhang

, Di

, Wang

, Cao

, Zhang

and Ma

: ‘Constitutive analysis of the hot deformation behavior of Fe–23Mn–2Al–0·2C twinning induced plasticity steel in consideration of strain’, Mater. Des., 2013, 44, 354–364.

22.

Liu

, Zhang

and Yan

: ‘Hot deformation behaviour and constitutive modelling of P92 heat resistant steel’, Mater. Sci. Technol., 2011, 27, 1281–1286.

23.

Wei

, Liu

, Zhao

and Kang

: ‘Hot deformation behavior of two C–Mn–Si based and C–Mn–Al based microalloyed high-strength steels: a comparative study’, Mater. Des., 2013, 50, 484–490.

24.

Mirzadeh

, Cabrera

, Prado

and Najafizadeh

: ‘Hot deformation behavior of a medium carbon microalloyed steel’, Mater. Sci. Eng. A, 2011, A528, 3876–3882.

25.

Kaibyshev

and Kazakulov

: ‘Deformation behaviour of Fe-3Si steel’, Mater. Sci. Technol., 2004, 20, 221–228.

26.

Rao

, Prasad

and Hawbolt

: ‘Hot deformation studies on a low-carbon steel: Part 1 – flow curves and the constitutive relationship’, J. Mater. Process., 1996, 56, 897–907.

27.

Chai

, Xu

and Guo

: ‘Prediction of constitutive behaviour of 20CrMnTiH steel under hot deformation conditions’, Mater. Sci. Technol., 2012, 28, 857–863.

28.

Zeng

, Zhang

and Jonsson

: ‘Deformation behaviour of commercially pure titanium during simple hot compression’, Mater. Des., 2009, 30, 3105–3111.

29.

Gao

and Luo

: ‘Hot deformation behavior of as-cast Mg–Zn–Mn–Ce alloy in compression’, Mater. Sci. Eng. A, 2013, A560, 492–499.

30.

, Hu

and Sun

: ‘Deformation behaviour and dynamic recrystallization of AZ61 magnesium alloy’, J. Alloys Compd, 2013, 580, 262–269.

31.

Zhang

, Jin

and Chen

: ‘Hot deformation behavior of Al–Zn–Mg–Cu–Zr aluminum alloys during compression at elevated temperature’, Trans. Nonferr. Met. Soc. China, 2011, 21, 437–442.

32.

Roebuck

, Lord

and Brooks

: ‘Measurement good practice guide no 3. Measuring flow stress in hot axisymmetric compression tests’, National Physical Laboratory, Teddington, Middlesex, UK, 2002.

33.

Bastier

, Maitournam

, Dang Van

and Roger

: ‘Steady state thermomechanical modelling of friction stir welding’, Sci. Technol. Weld. Join., 2006, 11, 278–288.

34.

Nandan

, Roy

, Lienert

and Debroy

: ‘Three-dimensional heat and material flow during friction stir welding of mild steel’, Acta Mater., 2007, 55, 883–895.

35.

Zhu

and Chao

: ‘Numerical simulation of transient temperature and residual stresses in friction stir welding of 304L stainless steel’, J. Mater. Process. Technol., 2004, 146, 263–272.

36.

Buffa

, Hua

, Shivpuri

and Fratini

: ‘A continuum based fem model for friction stir welding-model development’, Mater. Sci. Eng. A, 2006, A419, 389–396.

37.

Assidi

and Fourment

: ‘Accurate 3D friction stir welding simulation tool based on friction model calibration’, Int. J. Mater. Form., 2009, 2, 327–330.

38.

Schmidt

and Hattel

: ‘Modelling heat flow around tool probe in friction stir welding’, Sci. Technol. Weld. Join., 2005, 10, 176–186.

39.

Jacquin

, de Meester

, Simar

, Deloison

, Montheillet

and Desrayaud

: ‘A simple Eulerian thermomechanical modeling of friction stir welding’, J. Mater. Process. Technol., 2011, 211, 57–65.

40.

Ulysse

: ‘Three-dimensional modeling of the friction stir-welding process’, Int. J. Mach. Tools Manuf., 2002, 42, 1549–1557.

41.

Nandan

, Roy

, Lienert

and DebRoy

: ‘Numerical modelling of 3D plastic flow and heat transfer during friction stir welding of stainless steel’, Sci. Technol. Weld. Join., 2006, 11, 526–537.

42.

Chiumenti

, Cervera

, Agelet de Saracibar

and Dialami

: ‘Numerical modeling of friction stir welding processes’, Comput. Methods Appl. Mech. Eng., 2013, 254, 353–369.

43.

Santiago

, Lombera

, Urquiza

, Cassanelli

and de Vedia

: ‘Numerical modeling of welded joints by the “friction stir welding” process’, Mater. Res., 2004, 7, 569–574.

44.

Colegrove

and Shercliff

: ‘Development of Trivex friction stir welding tool. Part 2 – three-dimensional flow modelling’, Sci. Technol. Weld. Join., 2004, 9, 352–361.

45.

Colegrove

and Shercliff

: ‘3-Dimensional CFD modelling of flow round a threaded friction stir welding tool profile’, J. Mater. Process. Technol., 2005, 169, 320–327.

46.

Liechty

and Webb

: ‘Modeling the frictional boundary condition in friction stir welding’, Int. J. Mach. Tools Manuf., 2008, 48, 1474–1485.

47.

Assidi

, Fourment

, Guerdoux

and Nelson

: ‘Friction model for friction stir welding process simulation: Calibrations from welding experiments’, Int. J. Mach. Tools Manuf., 2010, 50, 143–155.

48.

Zhang

: ‘Comparison of two contact models in the simulation of friction stir welding process’, J. Mater. Sci., 2008, 43, 5867–5877.