Advances in friction stir welding of steel : Project HILDA

Toumpis, Athanasios and Galloway, Alexander and Cater, Stephen R. and Micallef, Daniel and Camilleri, Duncan and Poletz, Nicolas and Arbaoui, Larbi (2014) Advances in friction stir welding of steel : Project HILDA. In: Transport Research Arena (TRA2014), 2014-04-14 - 2014-04-17, CNIT, La Défense.

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A microstructure and property evaluation of friction stir welded DH36 6mm plate has been undertaken. The study examined a wide range of process parameters and, from this, a process parameter envelope has been developed and an initial process parameter set established that gives good welding properties. Thermo-mechanical deformation studies were developed to generate flow stress regimes over a range of stain rates and temperatures and these data will support the on-going local numerical modelling development. A preliminary thermo-fluid model has been developed to predict temperature and material flow during the FSW of steel grade DH36. In this model, materials are considered as highly viscous incompressible fluid. The welded material is flowing around the rotating tool thanks to the modelling of the friction at tool/workpiece interface. In parallel, a global numerical model is being developed to predict the inherent residual stresses and distortion of FSW butt welded assemblies often in excess of 6m long plate.