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Meshfree numerical simulation of hybrid friction stir welding with adhesive bonding

From National Research Council Canada

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Affiliation
  1. National Research Council of Canada. Automotive and Surface Transportation
  2. National Research Council of Canada. NRC Industrial Materials Institute
FormatText, Article
Conference12th International Friction Stir Welding (FSW) Symposium, June 26-28, 2018, Saguenay, QC, Canada
Subjectfriction stir welding; adhesive bonding; meshfree simulation; coupled thermo-mechanic; SPHriction-3D
Abstract
As interest for lightweight vehicles continues to increase, there has been significant progress in the development of hybrid joining approaches. A process that has been gaining interest is friction stir welding combined with adhesive bonding (FSW-AB). In the FSW-AB process, a lap joint is prepared with an uncured adhesive over the entire overlap region. Following the application of the adhesive, the FSW process is performed. Using this hybrid method can lead to improved joint strength as well as increased fatigue resistance. Furthermore, the adhesive acts as a sealant and protect the FSW joint from corrosion. Certainly the method is attractive; however, there are joint design aspects that must be considered such as the thermal degradation of the adhesive and the effect of the adhesive transport in the friction stir weld zone. In this work, a meshfree coupled thermo-mechanical simulation of the FSW-AB process is performed using SPHriction-3D. The set of continuum mechanics equations describing the physics of the FSW-AB process are cast into an amenable set of algebraic equations using a weak-strong form approach called smoothed particle hydrodynamics (SPH). This approach uses a Lagrangian frame of reference, making it ideal for predicting the movement and thermal history of the adhesive layer during the FSW process. Experimental results along with adhesive degradation profiles and infrared spectroscopy are compared to the simulation results. The article will focus on details of the meshfree simulation method as well as comparison between the simulation and experimental results. We will show that the numerical model is able to predict the extent and location of the adhesive degradation. Ultimately, the developed simulation approach is a powerful design tool for advanced hybrid joining methods such as the FSW-AB process.
Publication date
PublisherTWI Ltd.
In
  • Proceedings of the 12th International Symposium on FSW.
LanguageEnglish
Peer reviewedYes
NRC numberNRC-AST-038
NPARC number23004651
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Record identifier75b2ebb2-010b-4358-9746-7878a68730fa
Record created2018-12-04
Record modified2020-06-03
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