ERA

Download the full-sized PDF of Experimental studies and asymptotic scaling for the development of engineering tools to predict coupled heat transfer and plastic deformation in Friction Stir Welding (FSW)Download the full-sized PDF

Analytics

Share

Permanent link (DOI): https://doi.org/10.7939/R3736MC73

Download

Export to: EndNote  |  Zotero  |  Mendeley

Communities

This file is in the following communities:

Graduate Studies and Research, Faculty of

Collections

This file is in the following collections:

Theses and Dissertations

Experimental studies and asymptotic scaling for the development of engineering tools to predict coupled heat transfer and plastic deformation in Friction Stir Welding (FSW) Open Access

Descriptions

Other title
Subject/Keyword
Friction Stir Welding
FSW
Welding Temperature Model
Welding Torque Model
Effects of Tool Geometry
Welding Force Analysis
Welding Temperature Analysis
Type of item
Thesis
Degree grantor
University of Alberta
Author or creator
Tsui, Jordan A.
Supervisor and department
Mendez, Patricio (Chemical and Materials Engineering)
Gerlich, Adrian (Mechanical and Mechatronics Engineering)
Examining committee member and department
Mendez, Patricio (Chemical and Materials Engineering)
Gerlich, Adrian (Mechanical and Mechatronics Engineering)
Li, Leijun (Chemical and Materials Engineering)
Wiskel, Barry (Chemical and Materials Engineering)
Rajendran, Arvind (Chemical and Materials Engineering)
Department
Department of Chemical and Materials Engineering
Specialization
Materials Engineering
Date accepted
2016-07-18T10:03:38Z
Graduation date
2016-06:Fall 2016
Degree
Master of Science
Degree level
Master's
Abstract
A study of temperature, force, and torque was performed using a set of ten different friction stir welding (FSW) tools. It was observed that pin diameter had the most significant effect on steady state welding temperature followed by shoulder diameter having a smaller but measureable effect. Pin threading caused the smallest change, increasing welding temperature only a few degrees higher than a smooth surface pin. Comparisons between temperatures measured from the FSW tool and the base material showed that material deformation during welding often causes thermocouple position in the substrate to move which can result in inaccurate readings. Additionally, thermocouples located in the substrate failed to fully capture temperature changes caused by increases in the tool shoulder diameter. Forces measured along the x, y, and z axis were all directly related to the size of the pin and shoulder diameter with the pin having a greater influence. As pin or shoulder diameter were increased, forces along the three axes increased and vice versa. However, once pin diameter became large enough the addition of pin threading caused measured force to decrease due to increased welding temperature which softened the base material. Torque was also directly related to the size of the pin and shoulder diameter (i.e. as pin/shoulder diameter increased, measured torque increased). The one exception was for tools with small pin diameter which experienced high torque due to their inability to generate enough frictional heating which led to low welding temperature. Experimental results of welding temperature and torque were compared to an existing model of coupled heat transfer and plastic deformation. Analyzing a single material with the model yielded the best results, and the accuracy of theoretical welding temperature and torque for aluminum alloy 5059 was 94% and 85%, respectively. Accounting for the size of the tool shoulder in a correction function for the model improved predicted values of temperature and torque by ~5% over previous results that did not account for shoulder diameter.
Language
English
DOI
doi:10.7939/R3736MC73
Rights
This thesis is made available by the University of Alberta Libraries with permission of the copyright owner solely for the purpose of private, scholarly or scientific research. This thesis, or any portion thereof, may not otherwise be copied or reproduced without the written consent of the copyright owner, except to the extent permitted by Canadian copyright law.
Citation for previous publication

File Details

Date Uploaded
Date Modified
2016-07-18T16:03:38.821+00:00
Audit Status
Audits have not yet been run on this file.
Characterization
File format: pdf (PDF/A)
Mime type: application/pdf
File size: 6349622
Last modified: 2016:11:16 16:16:26-07:00
Filename: Tsui_Jordan_A_201607_MSc.pdf
Original checksum: dddeee8adedc210ccc3fb69366acd30b
Activity of users you follow
User Activity Date