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Materials Science and Engineering A 419 (2006) 381–388

Design of the friction stir welding tool using the


continuum based FEM model
G. Buffa a,b,∗ , J. Hua a , R. Shivpuri a , L. Fratini b
a The Ohio State University, Department of Industrial, Welding and Systems Engineering, 1971 Neil Avenue, 210 Baker Systems, Columbus, OH 43210, USA
b Dipartimento di Tecnologia Meccanica, Produzione e Ingegneria Gestionale, Università di Palermo, Viale delle Scienze, 90128 Palermo, Italy

Accepted 10 September 2005

Abstract
In friction stir welding (FSW), the welding tool geometry plays a fundamental role in obtaining desirable microstructures in the weld and
the heat-affected zones, and consequently improving strength and fatigue resistance of the joint. In this paper, a FSW process with varying pin
geometries (cylindrical and conical) and advancing speeds is numerically modeled, and a thermo-mechanically coupled, rigid-viscoplastic, fully
3D FEM analysis able to predict the process variables as well as the material flow pattern and the grain size in the welded joints is performed. The
obtained results allow finding optimal tool geometry and advancing speed for improving nugget integrity of aluminum alloys.
© 2005 Elsevier B.V. All rights reserved.

Keywords: FSW; FEM; Tool geometry; Material flow; Grain size

1. Introduction shape of the pin and the shoulder surface of the head, have a great
influence on both the metal flow and the heat generation due to
Friction stir welding (FSW) of butt joints is obtained by friction forces. Secondly, either the force superimposed on the
inserting a specially designed rotating pin into the adjoining rotating tool during the process or the tool sinking in the sheet
edges of the sheets to be welded and then moving it all along the has to be properly chosen, since the pressure generated on the
joint [1–3]. During the process, the tool rotation speed (R) and tool shoulder surface and under the pin end determines the heat
feed rate (Vf ) are combined in a way that an asymmetric metal generated during the process. Finally both the rotating speed
flow is obtained. In particular, an advancing side and a retreating and the feed rate have to be selected in order to improve “nugget
side are observed: the former being characterized by the “pos- integrity” that results in a proper microstructure and eventually
itive” combination of the tool feed rate and of the peripheral in good strength, fatigue resistance and ductility of the joint.
tool velocity while the latter having velocity vectors of feed and Among the key components of the FSW tool geometry are
rotation opposite to each other. A detailed observation of the the tool shoulder and the pin. While the shoulder is the main
material microstructure in the joint section by Nelson and co- source of heat generated during the process, the primary con-
workers [4] indicated that there exists an area located at the core straint to material expulsion and the primary driver for material
of the welding, called “nugget”, where the original grain and flow around the tool, the pin is the primary source for material
subgrain boundaries appear to be replaced with fine, equiaxed deformation and the secondary source for heat generation in the
recrystallized grains characterized by a nominal dimension of a nugget. Consequently, the geometry of both the shoulder and pin
few micrometers [1–5]. are important to the FSW process. Nugget integrity is therefore
Actually the effectiveness of the obtained joint is strongly primarily dependent on a well-designed pin [8].
dependent on several operating parameters [5–7]. First of all, Among the vast published literature on the FSW process, very
the geometric parameters of the tool, such as the height and the few publications study the effect of tool geometry on the pro-
cess variables. Notable research contributions are the following:
Kailas et al. [11] performed some tensile tests of specimens, stir
DOI of original article:10.1016/j.msea.2005.09.040.
∗ welded at varying pin angles; Prado et al. [12,13] studied the
Corresponding author. Tel.: +39 091 6657051; fax: +39 091 6657039.
E-mail addresses: g.buffa@dtpm.unipa.it (G. Buffa), hua.14@osu.edu final tool geometry due to tool wear finding that, even starting
(J. Hua), shivpuri.1@osu.edu (R. Shivpuri), abaqus@dtpm.unipa.it (L. Fratini). from a threaded pin, a self-optimized threadless and still effec-

0921-5093/$ – see front matter © 2005 Elsevier B.V. All rights reserved.
doi:10.1016/j.msea.2005.09.041
382 G. Buffa et al. / Materials Science and Engineering A 419 (2006) 381–388

tive pin shape is reached after a short welding distance; using 2D


and 3D CFD commercial software Colegrove and Shercliff [8,9]
numerically investigated the influence of pin shape on material
flow during FSW. In their paper, different pin shapes were com-
pared in terms of material flow and welding forces on the basis of
both a stick and a slip boundary condition at the tool-workpiece
interface. Although very useful information was obtained in this
research in order to optimize the tool pin geometry, it has to be
noted that the assumption of isothermal conditions limits the
accuracy of their model. Further details regarding 2D and 3D
modeling are found out in [10].
The purpose of the present research is to develop an effec-
tive methodology to optimally design weld tooling and pro-
cess parameters for friction stir welding with increased nugget
integrity. In particular a numerical model is developed for the
FSW welding process based on thermo-mechanically coupled
rigid-viscoplastic 3D FEM, and analysis is performed to pre-
dict the process variables, as well as material flow pattern in the
welded joints at varying pin angles and advancing speeds.

Fig. 2. Tool design showing geometric parameters.


2. Numerical model for FSW
Table 1
The commercial FEA software DEFORM-3DTM , which is
Geometrical properties of the tool set utilized
a Lagrangian implicit code designed for metal forming pro-
cesses, is used to model FSW. Workpiece is modeled as a Angle dpin (mm) Dshoulder (mm) Pin surface area (mm2 )
rigid-viscoplastic material, and the welding tool as a rigid body 0 3.0 10.0 26.3
(Fig. 1). As far as the workpiece material is regarded, AA7075 10 2.5 10.5 31.4
was modeled as described in details in [14]. Further model details 20 2.0 11.0 32.8
30 1.5 11.0 35.8
can be found in [14,15].
40 1.0 11.0 43.2

2.1. Tool models


Table 2
In order to obtain an effective vertical material flow, differ- The simulation plan for numerical experiments
ent pin shapes can be adopted such as a cylindrical threaded, a Advancing speed Tool pin angle
conical threaded or a smooth conical. Nevertheless it is noticed Vf (mm/min)
0 10 20 30 40
that tool threads wear during FSW quickly leading to a “self-
optimized” smooth pin surface [12,13]. For this reason a conical 50 FSW1 FSW2 FSW3 FSW4 FSW5
smooth pin shape was taken into account in this paper and a set of 100 FSW6 FSW7 FSW8 FSW9 FSW10
200 FSW11 FSW12 FSW13 FSW14 FSW15
simulations was performed at varying geometry designs. Fig. 2
includes tool design utilized. In particular, for all the pin geome-
tries selected, the same 2.8 mm pin height and a 0.5 mm fillet
angle were considered for the conical shape; and the shoulder
radius at the pin–shoulder interface were adopted; different val-
external radius was changed in order to maintain constant con-
ues of the bottom pin diameters (namely dpin ) and of the taper
tact surface between the workpiece and the tool shoulder itself,
as shown in Table 1.
All the simulations were performed using the same procedure
and process parameters; in particular a tool sinking of 0.1 mm, a
tool rotating speed of 1000 rpm, a nuting angle of 2◦ and varying
the advancing velocity according to Table 2.

3. Results and discussion

3.1. Effect of pin angle and advancing speed on


temperature

It is known that during the FSW process, joining is achieved


Fig. 1. The continuum based FEM model. through frictional heating between the tool and the sheet,
G. Buffa et al. / Materials Science and Engineering A 419 (2006) 381–388 383

Fig. 3. Temperature profile on top left surface for different tool angles: (a) FSW6, (b) FSW8 and (c) FSW10.

and plasticizing, mixing, and extrusion action of a rotating related to the distortion of the welded workpiece. The more uni-
pin–shoulder tool that moves between two parts being joined. form the temperature distribution along the thickness direction
The ultimate requirement for a FSW process is to create a certain of the workpiece, the less distortion in the welded workpiece
amount of friction heat that can keep the welding material in a will take place, especially for the thin sheet. It is observed that
well-plasticized state with a suitable temperature and to generate the increase in temperature is greater when the pin angle is
a high hydrostatic pressure along the joint line so that a sound small than that when pin angle is large. For example, when
diffusion weld can be generated with good nugget integrity. The pin angle changes from 0◦ to 10◦ and from 10◦ to 20◦ , tem-
heat generation in FSW is in direct proportion to deformation and perature increases more than 18 ◦ C, however when the pin angle
frictional energy generated in the welding. The latter depends on changes from 30◦ to 40◦ the temperature increase only about
the friction coefficient and friction area between the tool shoul- 2 ◦ C. This indicates that the effect of pin angle on the heat gen-
der and workpiece surface as well on the rotation speed of the eration during the FSW process is only relevant for the pin angle
welding head pin and the pressure applied to the welding head below a certain value. A similar relationship is also observed for
shoulder [15]. When the contact surface between tool shoulder maximum temperature at the sheet–pin interface. When the pin
and workpiece, the rotation speed and the tool sinking are kept angle is above 30◦ , there is almost no change in the maximum
constant, the friction area is determined by the tool geometry. temperature.
Fig. 3 shows the temperature profiles around weld zone for dif- Fig. 5 shows the temperature distribution in the FSW joint
ferent pin taper angles. It can be seen from this figure that the along the transverse section after a welding length of about
heat-affected zone expands as the pin taper angle increases. The 40 mm, as steady state conditions have been reached. It is
expansion of heat-affected zone can be mainly ascribed both to observed from this figure that the increase in temperature is
the increase in friction heat due to the large pin angle, which greater when the pin angle is small than when the pin angle is
increases the contact area between the welding pin and work- large. For example, when pin angle changes from 0◦ to 10◦ and
piece, and to the remarkable increase in deformation energy. from 10◦ to 20◦ , temperature increases more than about 18 ◦ C
The expansion of the HAZ is also visible in Fig. 4 that illus- while when the pin angle changes from 30◦ to 40◦ , the temper-
trates temperature profile in transverse direction of the weld zone ature increases only about 2 ◦ C. This indicates that the effect of
for different pin angles. A more uniform temperature distribu-
tion along the thickness of the sheet is obtained as pin angle
increases. The profile of temperature distribution is directly

Fig. 4. Temperature profile in a x–z section: (a) FSW10, (b) FSW8 and (c) Fig. 5. Temperature distributions along x–z section in FSW joint as a function
FSW6. of pin angle α (Vf = 100 mm/min).
384 G. Buffa et al. / Materials Science and Engineering A 419 (2006) 381–388

Fig. 7. Mean stress along a x–z section, advancing side.


Fig. 6. Maximum temperature in the tool vs. pin angle.

pin angle on the heat generation during the FSW process only 3.2. Effect of pin angle on hydrostatic stress distribution
exists when the pin angle is below a certain value.
Fig. 6 presents the maximum temperature in the welding tool As discussed above that the temperature generated in the
for different pin angles at different advancing speeds. This pic- weld zone increases with the pin angle which is favorable for
ture indicates that the maximum temperature increases with the the solid diffusion and plasticized mixing, hence, is helpful for
pin angle. However, the effect of pin angle on maximum tem- weld quality in terms of material flow [16]. Furthermore, large
perature in the FSW joint works only for some small pin angles. pin angle promotes high hydrostatic pressure in the weld zone,
For example, when the pin angle is above 30◦ there is almost which is significantly important for enhanced nugget integrity,
no change in the maximum temperature. What is more, higher Fig. 7. However, the high temperature and hydrostatic pressure
temperatures and a more remarkable variation with the pin angle also favor severe tool wear because both diffusion and abra-
are obtained with slower advancing speed, due to the increased sive wear, which are the main mechanisms in FSW welding tool
time to weld the same length. wear, increase with temperature and hydrostatic pressure.

Fig. 8. Effective strain distribution along a x–z section: (a) FSW9 and (b) at varying pin angle, Vf = 100 mm/min.

Fig. 9. Maximum effective strain distribution along a y–z section FSW9 (a), and at varying pin angle (b).
G. Buffa et al. / Materials Science and Engineering A 419 (2006) 381–388 385

Fig. 11. Maximum strain rate vs. pin angle.


Fig. 10. Strain rate distribution in weld zone of a x–z section at various pin
angles, Vf = 100 mm/min.

workpiece and, therefore, produce deeper and wider deformed


3.3. Effect of pin angle and advancing speed on strain zone than small pin angle does.
distribution Fig. 9 presents the maximum effective strain generated in
FSW joint along transverse section for different pin angles.
As it is known that the thermal history and the plastic Again the picture indicates that the maximum strain increases
deformation of the weld region are strongly relevant for the with the pin angle, with a more significant effect when the angle
microstructure of weld itself, better understanding of the effects is relatively small and a nearly steady condition when above a
of process parameters and tool geometry on the strain distri- certain value.
bution in the joint during the FSW is very helpful for optimal
design and control of the process. Fig. 8 illustrates the strain 3.4. Effect of pin angle and advancing speed on strain rate
distribution in the weld zone in the transverse section. It is seen
from this picture that the strain distributions are not symmetric In Fig. 10, the strain rate distribution at different pin angles for
about the weld line. For all pin angles, the maximum strains are a transverse section of the joint is presented. It is seen from this
on the material advancing side: in addition, the strain in the weld figure that the strain rate increases with the pin angle and the dis-
zone increases with the pin angle. The increase in strain is larger tribution of strain rate is asymmetric about the weld line, i.e., the
when the pin angle is below 20◦ than that when above 30◦ . A fur- maximum value appears in the welding advancing side. Fig. 11
ther observation can also be made: not only does the maximum shows the dependence of maximum strain rate on pin angle and
strain, but also the plastically deformed area increases with the advancing speed. It is indicated that the strain rate increases
pin angle. The large pin angle exerts more upsetting effect on the with the pin angle and approaches its asymptote after pin angle

Fig. 12. (a–f) Material flow patterns in weld zone at different pin angles (Vf = 100 mm/min).
386 G. Buffa et al. / Materials Science and Engineering A 419 (2006) 381–388

Fig. 13. Plot of: (a) vertical force and (b) advancing force vs. pin angle.

reaches a certain value. In addition, a significant increase is strength. Therefore, predicting welding force is very important
observed for advancing speed values higher than 50 mm/min, for tool designing in FSW [14]. Fig. 13 shows the advancing
highlighting that an extremely low speed is not suitable for force and vertical force as a function of pin angle and advanc-
achieving a sound welding. On the contrary, a smaller differ- ing speed. It is observed that both advancing and vertical forces
ence is obtained for higher speeds. increase with the pin angle until the forces reach a maximum
point (pin angle of 10◦ ), then decrease with the increase of pin
3.5. Effect of pin angle and advancing speed on material angle and reach to its asymptote regardless of the changes in the
flow pin angle. This trend of welding force as a function of pin angle
can be directly attributed to the effect of pin angle on the temper-
During welding, as long as the tool sinking is kept constant, ature and strain profile in the workpiece. As discussed earlier, the
the stresses that the tool is subjected to vary with pin angle. In heat-affected zone and thermo-mechanical affected zone expand
addition, material flow pattern and flow rate are also strongly with the pin angle while the temperature increases as the pin
dependent on pin angle. The present FSW model is able to angle increases. The welding force is a competition between the
investigate the material flow in the weld zone. The material flow work hardening due to the upsetting on the workpiece and soft-
patterns at different pin angle are shown in Fig. 12a–f, where the ening of the workpiece due to increase in temperature. When pin
arrows represent the material velocity vectors. It can be observed angle changes from 0◦ to 10◦ , the expansion of HAZ and TMAZ
from this figure that just a small vertical material flow is observed is small and the work hardening effect due to the upsetting caused
with a cylindrical pin [16]. On the contrary, conical pin causes an by pin angle is stronger than the softening effect caused by tem-
additional down flow pattern, which becomes more remarkable perature increase in HAZ and TMAZ. Therefore, welding forces
as pin angle increases (Fig. 12b and c). Furthermore, it can be increase sharply. As the pin angle further increases, the HAZ and
referred from this Fig. 12d–f that a helical movement is produced TMAZ further expand and the temperature in HAZ and TMAZ
by the conical pin due to the circular movement component in goes up greatly which causes the softening effect overcome the
the horizontal (x–y) plane, Fig. 12d, and another circular move- work hardening effect resulting in reduction in welding forces.
ment component in vertical (y–z) plane, Fig. 12e and f. This will After a certain value of pin angle (20◦ in this research), the com-
produce more uniform plastic deformation in the weld zone and petition of work hardening and softening balance each other and
is favorable for achieving fine grain size microstructure. the welding force reaches its asymptote.

3.6. Effect of pin angle and advancing speed on welding


forces

The tool/pin during FSW is subjected to considerable forces


that may cause it to break if it does not have sufficient mechanical

Fig. 15. Minimum grain size dimension at varying pin angle and advancing
Fig. 14. Distribution of the Zener–Hollomon parameter in weld zone for FSW9. speed.
G. Buffa et al. / Materials Science and Engineering A 419 (2006) 381–388 387

Fig. 16. Predicted grain size distribution for FSW7 and FSW10 at z = 1.5 mm (a) and actual grain in the FSW 7 weld nugget (b).

3.7. Effect of pin angle and advancing speed other hand, nugget area obtained by cylindrical pin is smaller
Zener–Hollomon parameters, grain size and joint resistance than that by conical pin resulting in negative influence on joint
resistance. Based on the above discussion, it’s concluded that
Microstructural evolution takes place during FSW due to with a bigger pin angle there’s a significant increase in nugget
mechanical stirring and continuous dynamic recrystallization area, namely the core of the welding where the grain size is in
(CDRX) effects [17–21] resulting in a highly refined grain struc- the order of 2–5 ␮m [21,22], which eventually leads to enhanced
ture in the weld nugget and strongly affecting the final joint nugget integrity.
resistance. The grain size of 7XXX series aluminum alloys dur-
ing CDRX is strongly dependent on strain and Zener–Hollomon 4. Summary and future work
parameter, a function of strain rate and temperature. In addition
to predicting strain distribution, the present FSW model is also A thermo-mechanical fully coupled 3D FEM analysis is per-
used to predict Zener–Hollomon parameter in the weld zone. formed for investigating the effect of pin angle on the FSW
Fig. 14 illustrates the Zener–Hollomon parameter distribution process. Based on the above discussions, the following conclu-
in the weld for FSW9. The process characteristic zones, namely sions are drawn:
nugget, TMAZ and HAZ, are well highlighted in the model,
which are very useful for predicting microstructural evolution • Increasing the pin angle enlarges both the heat-affected zone
during FSW process. and thermal mechanical zone resulting in a bigger weld
In these zones, material undergoes a continuous dynamic nugget. The overall temperature in weld zone increases with
recrystallization process, which eventually leads to the replace- pin angle. In addition, increase in the pin angle leads to uni-
ment of the original grain and sub-grain boundaries with fine, form temperature distribution along sheet thickness, which is
equiaxed recrystallized grains. CDRX process, as the well- favorable for the reduction of distortion.
known DRX, is affected by a few variables; the final dimension • The plastic deformation in the nugget increases with the
of the continuously recrystallized grain (d) is mainly influenced pin angle. However, the maximum deformation reaches its
by the local value of the Zener–Hollomon parameter (Z), and, asymptote as the pin angle is above a certain value. Similarly,
of course, by the selected material constants [22]. the strain rate increases with the pin angle until a critical value.
1 After this value, strain rate reaches its asymptote.
d= with a = −3.43 and b = 0.162 (1) • Using a conical pin in FSW produces a helical movement
a + b ln(Z)
in the weld zone. This movement causes material flow down
Fig. 15 shows how the minimum grain size is influenced by the in the leading edge and flow up in the trailing edge. This
pin angle: as mentioned above both temperature and strain rate increases the material circulation and leads to more uniform
increase with pin angle. As it is known, an increase in temper- thorough thickness distribution of parameters such as strain,
ature leads to an increase in grain size and, on the contrary, an strain rate and temperature.
increase in strain rate leads to a decrease in grain size. Fig. 16a • A significant refinement in the grain size is observed when
and b illustrates the predicted grain size distribution for two dif- advancing speed increases from 50 mm/min to 100 mm/min.
ferent pin angles and the actual grain in the nugget of FSW 7. The On the contrary, such a difference in minimum grain size
predicted results in Figs. 15 and 16a indicate that the effect of is not observed for higher speeds. At the same time, a sig-
temperature is somewhat dominant for the grain growth reason nificant increase both in the vertical and in the advancing
being the slower advancing speed leads to a higher temperature welding forces is observed when advancing speed increases
in the nuggets resulting in a larger grain size. Although a cylin- from 100 mm/min. to 200 mm/min. Finally a more uniform
drical pin is helpful for obtaining a smaller grain size, on the temperature and grain size distribution, as well as a wider
388 G. Buffa et al. / Materials Science and Engineering A 419 (2006) 381–388

nugget area are obtained at increasing pin angle. Based on [3] M. Guerra, C. Schmidt, L.C. McClure, L.E. Murr, A.C. Nunes, Mater.
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713–729.
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Friction Stir Welding, Park City, 2003.
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