101

Department of Mechanical and Electro-Mechanical Engineering

National Sun Yat-sen University
Master Thesis

Numerical model for theoretical and experimental studies of

temperature and material flowduring friction stir spot welding

Hsin Tsung Lai

Dr. Rong-Tsong Lee

Dr. Yuang-Cherng Chiou

102 7
July 2013

Department of Mechanical and Electro-Mechanical Engineering

National Sun Yat-sen University
Master Thesis

Numerical model for theoretical and experimental studies of

temperature and material flowduring friction stir spot welding

HSIN-TSUNG LAI

Rong-Tsong Lee

Yuang-Cherng Chiou

102 7
July 2013
ii

( )(

du
)
dz

(1.3)(plunge force)

ii

Abstract
The present study was to investigate the friction stir spot welding (FSSW) process,
material flow and temperature behavior without probe,using Finite Difference Method to
simulate and analyze the material flow and temperature changes and compare with
experiment in the welding process. Use cylindrical coordinates to create a three-dimensional
steady-state friction stir welding process model. The theoretical simulation of fluid dynamics
based model, while solving the continuity equation, momentum conservation, and energy
balance equations.
The speed of surface close to the workpiece are assumed to be known in past studies.
This study is divided into two parts, Where in pure sliding portion, assuming that the surface
speed of the material is zero, partial sticking is assumed that the surface speed is unknown,
The calculation of surface speed on workpiece let the shear stress of the tool equal to
viscous shear stress of material. Finally, we discuss the temperature rise and the effect of
sticking ratio by pressure or plunge force on the workpiece.
The study found that start generating the material flow of the workpiece is not always
occur by high temperature point, but with the friction coefficient and pressure. The study also
found that the sticking occurs in the direction from the center of the workpiece to the
shoulder edge. In the experiment ,the state to achieve full sticking in the shoulder edge, is
almost impossible happen.

Keywords: FSSWCylindrical coordinatesspeedstickingpressure

iii


..................................................... ii
.................................................... iii
....................................................... iv
....................................................... vi
..................................................... viii
..................................................... ix
.................................................. 1
1.1 ....................................... 1
1.2 .............................................. 3
1.3 .............................................. 8
1.4 .............................................. 9
............................................. 10
2.1 ........................................ 11
2.2 ........................................... 16
2.3 ............................ 21
2.4 ............................................. 22
........................................... 27
3.1 ...................... 28

iv

3.2 ...................... 36
3.3 ........................ 39
3.4 .................. 42
3.5 ................ 44
................................................. 48
..................................................... 50


1.1 [2].................................. 1
1.2 [4].................................... 2
1.3 [5].................................... 3
1.4(a) ............................. 6
1.4(b) [21] ......................... 6
1.5 ............................. 8
2.1 ( r , , z ) ................................... 10
2.2
( 10) (Pa s) ................... 15
2.3
( 10) (Pa s) ................... 16
2.4 ............................ 18
2.5 ............................ 19
3.1(a)(b) ( = 1200 rpm)(p=25MPa) ...... 29
3.1(c)(d) ( = 1200
rpm)(p=25MPa) ......................................... 30
3.2 ( 1200 rpm) ........... 32
3.3 ( 1200 rpm) ........... 34

vi

 3.4 ( 1200 rpm) ............. 35

3.5 ( 800 rpm) ............ 37
3.6 ( 800 rpm) ............ 38
3.7 ( 28.75 MPa) ........ 40
3.8 ( 28.75
MPa) ........ 41
3.9 ()
............................................. 43
3.10 ()
............................................... 43
3.11 [27] .................................... 44
3.12

(a) (b) ....................... 45

3.13 ( 28.75 MPa 800

rpm)................................................... 45
3.14 (
28.75 MPa 800 rpm) ............................. 46
3.15 (
28.75 MPa 800 rpm)........................... 47

vii


2.1 ....................................... 14
2.2 ....................................... 14

viii

....................................................

....................................................

TA

....................................................

h1

....................................

..........................................

..........................................

............................................

....................................................

Cp

....................................................

vr

......................................... r

.........................................

vz

......................................... z

............................................

................................................

....................................................

....................................................

ix

1.1

1991 Thomas [1]

friction stir welding , FSW
(base metal)

1-1 (tool)pin
shoulder

1-1 [2]
1


friction stir spot welding , FSSW
GKSS ()
[3] FSW
(plunging)
(stirring)(retracting)
1-2 /

1-2 [4]

FSSW (pin hole)(key

hole)
1-2(c)
Bakavos and Prangnell [5]

1-3 (pinless tool)

Bakavos[6]

 1-3 [5]

FSSW

1.2

FSSW

FSSW FSW FSSW

FSW
FSSW

 FSW

FSW
(Fluid mechanics base model) [7-15]

(sticking)(sliding)

(Solid mechanics base model) [16-19]

FSSW
Kakarla[16]
FSSW
1-2 (a) FSSW
Awang[17]

(5 mm/s)
4

(1 mm/s) 29 %
Hirasawa [18] FSSW

Coulomb

=p

(1.1)

p
Colligan [20]
1-4 a
K (the shear flow stress)

1-4 b Tresca
(yield criteria)K = 0.5 f f
= 0.5 p = f max p max
1-4 b
= K
(sticking friction)

 = mK

(1.2)

m Tresca m 0 1 m 1 (sticking)K
von-Mises K= f

1-4 (a)
(b) [21]

Nandan [22-23]

= K + (1 ) p

(1.3)

1 0 =0
6

(pure sliding) p =1
Coulomb Tresca

Liechty and Webb [24]

(a sticking constant velocity)(no-slip)
(a slipping variable shear stress model)
Coulomb Tresca
1/ b

= mK 1 exp( p / k )b

(1.4)

Nandan [19-20]
= mK Tresca n =
= p Liechty and Webb [22](
)

1-5 (250
rpm) 1000 rpm
( f )(107
MPa)( f )

1-5

2010 [25]
2011 [26]

1.3

--
Nandan[22-23]

( )(

du
)
dz

(1.3)(plunge force)

1.4


FSSWFSW
FSSW
( r , , z )FSSW

2-1

FSSW

2-1 ( r , , z )

10

2.1

[27]

FSSW
( / = 0 )
(body force, FB )

( vr = 0 vz = 0 )

vr vr 1 v vz
+ +
+
=0
r r r
z

( 2.1 )

v r , , z r , , z
vr = vz = 0 ( 2.1 )
v
1 v
=0 =0
r

( 2.2 )

v v r z

v v v v v
v
v
+ vr + + r + vz
r
r
r
z
t
1

1 p
= 2 ( r 2 r ) +
+ FB
+ z
r
z r
r r

( 2.3 )

rr zz (normal stress)
11

 rr = 2

vr
r

1 v vr
+
r r

= 2

zz = 2

vz
z

( 2.4 )

r z rz (shear stress)

1 v

r
r = +
= r

r
r
r

1 vz v
+
= z
r z

z =

( 2.5 )

( 2.6 )

rz = r + z = zr
z r

( 2.7 )

(2.4)(2.7)(2.3)

1 2 v v 1 vr 1
r
+
+
r 2 r
r r r
r

1 v vr 1 vz v
2 r + r + z r + z = 0

( 2.8 )

( 2.8 )
2 v v
2 +
r r
r

2
v
+

2
z

1 v v 1 v
+
=0
+

r z z
r r

( 2.9 )

Sheppard Wright [28]

e &

12

 1
Q
e = sinh & exp

A
RT

( 2.10 )

2-1
A n [22]
A (%C ) n
[23]

A = 1.8 106 + 1.74 108 (%C ) 6.5 107 (%C ) 2

( 2.11 )

= 1.07 + 1.70 104 T 2.81107 T 2

( 2.12 )

n = 0.2 + 3.966 10 4 T

( 2.13 )

Q R & [23]

& =

2
(&ij&ij )
3

( 2.14 )

&ij

1 ui u j
+

2 x j xi

&ij =

13

Property/Parameter
Workpiece length (x-direction )
Workpiece length (y-direction )
Shoulder radius
Rotational speed
Workpiece-material
Density
Plunge pressure, PT
Coefficient of friction
Heat transfer coefficient
A, material constant
, material constant
n, material constant
Q, activation energy
Thermal conductivity of solid

value
60 mm
40 mm
6 mm
800 rpm
Al-6061-T6
3
2700 kg/ m
28.75 Mpa
0.5
2
30 W/m -K
6 -1
8.8610 s
-1
0.045 (MPa)
3.55
145 kJ/mol
25 W/m-K

2-1

Property/Parameter
Workpiece length (x-direction )
Workpiece length (y-direction )
Shoulder radius
Rotational speed
Workpiece-material
Density
Plunge pressure, PT
Coefficient of friction
Heat transfer coefficient
Q, activation energy
Thermal conductivity of solid

value
60 mm
40 mm
10 mm
1200 rpm
SS400
3
7860 kg/ m
25 Mpa
0.5
2
50 W/m -K
145 kJ/mol
25 W/m-K

2-2

14

 Perzyna ' s [29](flow stress) f

&

f
3&

( 2.15 )

2-2

2-3

( 105 Pa s )( 106 Pa s )

400

5.
15
01

350
300 5.4
49

5. 1
50
1

250

200

150

5. 1
50 1

5.4
49
5.44
9

5.7
48

100

5.449

5. 748
6. 046
9

5.748

50

6.046 9

6.3459

350

400

450

500

6.345 9
550
600

6. 0469

650

700

750

800

2-2
( 10) (Pa s)

15

400

4.
65
14

350

Strain rate (s-1)

4.
300 951
9

4.6
51
4

250
4.6
51 4

4.9
51
9

200

4.95
1

150 5. 25
24
100

50
350

9
4.951
9

5.252
4

5.252 4

5.552 8

5. 853 3

400

450

5.552 8

5. 8533
500
550

600

650

700

5.552 8
750
800

2-3
( 10) (Pa s)

2.2

1 T
kr
r r r

1 T T
+ 2
k
+ k
r z z

+ = 0

( 2.16 )

T k

16

 v
= rr r
r

v 1 vr
r r r + r

1 vz v
v v
+ z
+
+ rz z + r

r z
r z

1 v vr

v
+ + zz z
+

z
r r

+ r

( 2.17 )

FSSW ( / = 0 )( 2.9 )

T
k
r r

1 T T

+ k
+k
r r z z

+ = 0

( 2.18 )

vr = vz = 0 v r z

v
= r r
r r

v
+ z z

( 2.19 )

( 2.5)( 2.6)( 2.19)( 2.14)

= 3 & 2

( 2.20 )

FSSW TA = 298 K

q1

q1 = K C f + (1 ) p r

, 0 r RS

17

( 2.21 )

 C f
C f = 1 p RS

q1
(sticking)10 = 0
(pure sliding) = 1
K
von-MisesK= f

3 f

2-4
2-5
f
(heat flux continuity)

T
z

top

JW
q1
JW + J T

, 0 r RS

( 2.22 )

J w q1 J T [23]
(k C p )W
JW
=
JT
(k CP )T

18

250

SS 400

Yield strength, MPa

200

150

100

50

0
700

800

900

1000

1100

1200

1300

Temperature, k

2-4

2-5

19

1400

1500

T
z

top

( 2.23 )

= h1 (T TA )

h 1
[22-23]

T
z

bottom

( 2.24 )

= h2 (T TA )

h2

20

2.3

( i )( = 0 )
( ii ) ( 0 < 1 )
( p )( k )(1.3)
( )(

du
)
dz

K + (1 ) p =

du
dz

0 < 1

( 2.25 )

(2.9)(2.14)

T
k
r r

1 T

+
( KC f + (1 ) p ) r + = 0
+k
r r z

0 < r RS
( 2.26 )

(2.9)(2.15)

T
k
r r

1 T T

+ k
+k
r r z z

+ = 0

r > RS
21

( 2.27 )

2.4
F1 F2
(Newton-Raphson Method) v T
F1
v

F1
v

F2
T v
F

= 1

F2 T
F2

F1 (2.9)

2v
v
F1 = 2 +
r r
r

2
v
+

2
z

2
2
1 & v v v v

+ &
r r + z = 0

v r

(2.28)

CT =

Q
1
exp
RT
A
i ,k

xi ,k = (CT &i ,k ) n

(2.29)

(2.10) f

22

f =

1
1
sinh 1 ( CT &i ,k ) n = sinh 1 ( xi ,k ) = ln xi ,k + xi ,k 2 + 1

)
(2.30)

(2.22)(2.15)(2.20)

1 & 1

=
& v i ,k
=

1 f
2 &r ,i , k
1
f

2
3&i ,k &i ,k 3&i ,k
3 ri&i ,k

1 i , k
1
+

i ,k &i ,k 3&i ,k

xi ,k 2 &r ,i , k

1
2

x + 1 n& 3 ri&i ,k

3&i ,k
1
=
+
2
&i ,k ln x + x + 1

2
=
3ri

xi ,k
1

2
2
n 1 + xi , k ln xi ,k + xi ,k + 1

3&i ,k

&r ,i ,k
& 2
i ,k

xi , k
1

2
1 + xi ,k n&i ,k

2 &
r ,i , k

3 ri&i ,k

(2.31)

(2.23)(2.20)

V 2Vi ,k + Vi 1,k
1 Vi +1,k Vi 1, k Vi ,k +1 2Vi ,k + Vi ,k 1
F1 = i +1,k
+

+
2

z 2
r
2
r
r
r
i
+
1
i

xi ,k
2
&r ,i ,k
+ 1

3ri n 1 + x 2 ln x + x 2 + 1
&i ,k
i ,k
i ,k

Vi +1,k Vi 1,k 2 Vi ,k +1 Vi ,k 1 2 Vi ,k Vi +1,k Vi 1,k

2r
2z
ri
2r

Q
1
xi ,k = ( exp
RT
A
i ,k

&

)
i ,k n

(2.24)
23

= 0

(2.32)

( )(

F1 = KC f + (1 ) p

du
=0
dz

0 < 1

du
)
dz

( 2.33 )

Vi ,1 i ,1
ri

V V
V
C f + 1 i ,1 pi ,1 i ,1 i ,1 i ,2 = 0
z
3
ri

( 2.34 )

F2 =

T
k
r r

1 T T

+ k
+k
r r z z

+ = 0

(2.35)

k
k
k
k
k
F2 = i , k2 i ,k Ti 1, k + i +1,2k + i ,k Ti +1, k + i ,k2 Ti ,k 1
2ri r
2ri r
z
r
r
k
+ i ,k +21 Ti ,k +1 +3i ,k &i ,k 2 = 0
z

(2.36)

(i) (2.18)

24

 ( ki +1,1 + ki ,1 ) ( ki ,1 + ki ,2 )
ki ,1
ki ,1
ki ,1
ki +1,1
F2 =

Ti ,1 + 2
Ti 1,1 + 2 +
Ti +1,1
2
2
r
z
2ri r
2ri r

r
r
( ki ,1 + ki ,2 )

V
2 Vi ,1 i ,1
+
C f + 1 i ,1 pi ri +3i ,k &i ,k 2 = 0
Ti ,2 +
2
z ri 3

ri

(2.37)

(ii) (2.15)

(2.28)
( ki +1,1,t + ki ,1,t ) ( ki ,1,t + ki ,2,t ) 2h
k
k

1 Ti ,1,t + i ,1,2t i ,1,t Ti 1,1,t

F2 =
2
2
r
z
z
2ri r

r
( ki ,1,t + ki ,2,t )
k
k
2
2
+ i +1,1,2 t + i ,1,t Ti +1,1,t +
Ti ,2,t h1 ( TA ) +3i ,k &i ,k = 0
2
z
2ri r
z

(2.38)

r T r = 0
(2.28)

( k2, k + k1,k ) k1,k k1, k +1

k + k
k
F2 =
2
T1,k + 2,k 2 1,k T2,k + 1,k2 T1,k 1
2
2
r
z
z
r

+ 1, k +21 T1,k +1 +3i ,k &i ,k 2 = 0

z

(2.39)

(2.16)(2.28)

25

 ( ki +1,k + ki ,k ) ( ki ,k + ki , k 1 ) 2h
k
k
F2 =

Ti ,k + i ,k2 i ,k Ti 1,k
2
2
r
z
z
2ri r

k
k
k + k
2
+ i +1,2k + i ,k Ti +1, k + i , k 2i ,k 1 Ti ,k 1 h (TA ) +3i ,k &i ,k 2 = 0
z
2ri r
z

r
(2.40)

26


(FSSW)

FSSW

(FSSW)

""
(FSSW)

FSSW (plunge force)

r z v

27

3.1

(r)(z)
2-1
(1200 rpm)(p=25MPa)

3-1 (a)

3-1 (d)

3-1 (c)(r)(z)(z
) 2 mm r
Perzyna ' s [29]

3-1 (d)
r

3-1 (b)(r)
r

28

1400
1300

Z (mm)
0
2
4
6
8

1200
1100
Temperature (oC)

1000
900
800
700
600
500
400
300
200
100
0
0

8 10 12
Radius (mm)

14

16

18

20

1400
1300

Z (mm)
0
2
4
6
8

1200
1100
Velocity (mm/s)

1000
900
800
700
600
500
400
300
200
100
0
0

3-1

4
6
Radius (mm)

10

( a ) ( b ) ( = 1200 rpm)(p=25MPa)

29

100
0
2
4
6

90
80

viscosity MPa

70
60
50
40
30
20

Z (mm)

10
0

10
R (mm)

12

14

16

18

20

2
2
4
6

1.8
1.6
1.4

Z (mm)

strain rate

1.2
1
0.8
0.6
0.4
0.2
0

3-1

5
R (mm)

10

( c ) ( d ) ( = 1200 rpm)(p=25MPa)

30

 3-1 (a) 10 mm r
10mm

r 9~10 mm

3-2

3-2(d)
1250 C ( 1500 C )
( 3-2(d)) p=25 Mpa( 3-2(c))
(r = 0) 220 C
FSSW

(T)(r)(r=10)
r=10 FSSW
( 3-2)

31

1400

1400

1300

0
2
4
6
8

1100
1000
900

1000

700
600
500

800
700
600
500
400

300

300

200

200

100

100

0
4

8 10 12
Radius (mm)

14

16

18

20

1400

8 10 12
Radius (mm)

14

16

18

20

8 10 12
Radius (mm)

14

16

18

20

1400

1300

1300

Z (mm)
0
2
4
6
8

1100
1000
900

1200
1100
1000
Temperature (oC)

1200

Temperature (oC)

900

400

0
2
4
6
8

1100

800

Z (mm)

1200

Temperature (oC)

1200

Temperature (oC)

1300

Z (mm)

800
700
600
500

900
800
700
600
500

400

400

300

300

200

200

100

100

0
0

8 10 12
Radius (mm)

14

16

18

20

Z (mm)
0
2
4
6
8

3-2 ( 1200 rpm)

32

 3-3 (p=10MPa)

3-3 (b)(c) r = 8.7 mm

3-3 (c)(d)
p=25 MPa r < 7 rmm
7 < r < 10 mm

()
3-3(d)
r = 10 mm
z

(z=0)
3-4

(p=20MPa)(z=0)
25MPa 5 MPa r 3
FSSW ''''

(6061-T6) 350 C

33

1400

1400

1300

0
2
4
6
8

1100
1000
900

0
2
4
6
8

1100
1000

800
700
600
500

900
800
700
600
500

400

400

300

300

200

200

100

100

0
0

4
6
Radius (mm)

10

1400

4
6
Radius (mm)

10

4
6
Radius (mm)

10

1400

1300

1300

Z (mm)
0
2
4
6
8

1100
1000
900

1000

700
600
500

900
800
700
600
500

400

400

300

300

200

200

100

100

0
2

4
6
Radius (mm)

0
2
4
6
8

1100

800

Z (mm)

1200

Velocity (mm/s)

1200

Velocity (mm/s)

Z (mm)

1200

Velocity (mm/s)

1200

Velocity (mm/s)

1300

Z (mm)

10

3-3 ( 1200 rpm)

34

1.1
1
0.9
0.8

0.7
0.6
0.5
p=10 MPa
p=20 MPa
p=25 MPa
Full-sticking

0.4
0.3
0.2
0.1
0
0

4
6
Radius (mm)

10

3-4 ( 1200 rpm)

35

3.2

2-2 (800 rpm) p

3-5
3-6
( 3-6) r
z
6 mm r 6mm

3-5 r 5~6 mm

3-5

3-6 ( )
(p=10MPa)

3-6

3-6 (b)(c)

3-6 (c)(d)(0 mm)(0.5 mm)

FSSW

2-2(8 KN)(800 rpm)

1.5 mm475 C (485 C )

3-5 (c)

36

( a ) p = 10 MPa

( b ) p = 20 MPa

800

800
Z (mm)

700

500
400
300

500
400
300

200

200

100

100

0
0

4
6
Radius (mm)

10

( c ) p = 28.75 MPa

4
6
Radius (mm)

10

10

( d ) p = 41 MPa

800

800
Z (mm)

700

700

0
0.5
1
1.5
2

500

600
Temperature (oC)

600
Temperature (oC)

0
0.5
1
1.5
2

600
Temperature (oC)

Temperature (oC)

600

Z (mm)

700

0
0.5
1
1.5
2

400
300

500
400
300

200

200

100

100

0
0

4
6
Radius (mm)

10

Z (mm)
0
0.5
1
1.5
2

4
6
Radius (mm)

3-5 ( 800 rpm)

37

0.0005

0.0005

Z
0
0.5
1
1.5
2

0.0002

0.0003

0.0002

0.0001

0.0001

0
0

4
6
Radius (mm)

0
0.5
1
1.5
2

0.0004

V (mm/s)

0.0003

10

Radius (mm)

0.1

120
Z

Z
0
0.5
1
1.5
2

0.08

0.06

0
0.5
1
1.5
2

80
V (mm/s)

V (mm/s)

V (mm/s)

0.0004

0.04

40

0.02

0
0

4
Radius (mm)

Radius (mm)

3-6 ()

38

3.3

3.2(28.75 MPa)

2-2
3-7
3-8

3-7 (a)(b)250 C

3-7 (b)(d) 150 C

3-7 (b)(c)
125 C
3-7 (c)(d)
125 C

39

( a ) 200 rpm

( b ) 600 rpm

800

800
Z (mm)

700

500

0
0.5
1
1.5
2

600
Temperature (oC)

Temperature (oC)

600

Z (mm)

700

0
0.5
1
1.5
2

400
300

500
400
300

200

200

100

100

0
0

4
6
Radius (mm)

10

( c ) 800 rpm

4
6
Radius (mm)

10

4
6
Radius (mm)

10

( d ) 1000 rpm

800

800
Z (mm)

700

700

0
0.5
1
1.5
2

500

600
Temperature (oC)

600
Temperature (oC)

400
300

500
400
300

200

200

100

100

0
0

4
6
Radius (mm)

10

Z (mm)
0
0.5
1
1.5
2

3-7 ( 28.75 MPa)

40

( a ) 200 rpm

( b ) 600 rpm

0.05

0.005

Z
0.04

0.03

0.02

0.003

0.002

0.01

0.001

0
0.5
1
1.5
2

0.004

V (mm/s)

V (mm/s)

0
0.5
1
1.5
2

( c ) 800 rpm

( d ) 1000 rpm

0.1

0.8
Z

Z
0
0.5
1
1.5
2

0.08

0.06

0
0.5
1
1.5
2

0.6

V (mm/s)

V (mm/s)

Radius (mm)

Radius (mm)

0.04

0.4

0.2
0.02

0
0

Radius (mm)

4
Radius (mm)

3-8 ( 28.75 MPa) ()

41

3.4

()

3.9
3.10 M 3.1 P
3.2
M =

contact

(r

ri 12

P = M

3.1
3.2

3.9 40 MPa
40 MPa

( tool )
3.3 ( material ) Von-Mises
3.4

tool = p

material =

y
3

3.3
3.4

tool = material 3.33.43.5

y = 3 p

42

3.5

1400

20

1300

1400

1200
16

900
800
12

700
600
500

Power (W)

1200

1000

Torque (Nm)

Temperature (oC)

1100

1000

800

400

Temperature
Torque
Power

300
200
100

600
4

400
8

12

16

20

24

28

32

Pressure (MPa)

Temperature (oC)

600

20

1000

16

800

500
12
400
8
300

Temperature
Torque
Power

200

100
0

20

40

60

Torque (Nm)

700

600

400

200

Power (W)

3.9 ()

80

Pressure (MPa)

3.10 ()

43

3.5

3.11

3.11 [27]

Bakavos[6]

(SKH51)
3.12 (a)
60mm 20 mm 3mm 6061-T6
3mm K-type P
1.5mm

3.12 (b)

44

30
60

Jo
in

tl

in
e

(b)

3.12 (a) (b)

3.12 (b)#400

2.1
P
P

P
1% NaOH 120s 15% HNO3
1.5

3.13

3.13 ( 28.75 MPa 800 rpm)

45

 3.14 28.75 Mpa 800 rpm

( r = 0 mm ) 1.5 mm ( Z = 1.5 mm )
RZ

3.15

1.7 mm

800
Z (mm)

700

0
0.5
1
1.5
2

Temperature (oC)

600
500

1.5mm

400
300

475 C

481 C

200
100
0
0

4
6
Radius (mm)

10

3.14
( 28.75 MPa 800 rpm)

46

9
8
7
6

Z (mm)

V(theta) (mm/s)

5
4
3
2
1

3.15
( 28.75 MPa 800 rpm)

47

( )(

du
)(plunge force)
dz

(1200 rpm)p < 16 MPa

16~30 MPa
p > 30 MPa

(800 rpm)p < 18 MPa

18~41 MPa
41 MPa

1 ( = 1 )

48

49


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[3] Patent application DE 199 55 737.3 with foreign patent application
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[4] M. Awang,V. Mucino ,Z. Feng and S.David;Thermo-Mechanical
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and anvil insulation on friction stir spot welding thin gauge 6111
automotive sheet
[6] D. Bakavos and P. B. Prangnell;Material Interactions in a Novel
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Sheet.
[7] . FRIGAARD, . GRONG, and O.T. MIDLING; A Process Model
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Metallurgical and Materials Transactions A, Vol.32A
(2001),1189-1200.
[8] YUH J. CHAO, and XINHAI QI; Thermal and Thermo-Mechanical
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(1998) 215-233.
[9] H. Schmidt, J. Hattel and J. Wert; An analytical model for the heat
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Eng. 12 (2004) 143157.

50

[10] A. De, T. DebRoy. Weld J. 84 (2005) 101.

[11] A. De, T. DebRoy. J Phys D: Appl Phys 37 (2006) 140.
[12] A. Kumar, W. Zhang, T. DebRoy. J Phys D: Appl Phys 38 (2005)
119.
[13] A. Kumar, T. DebRoy. Int. J. Heat Mass Transfer 47 (2004) 5793.
[14] O. Zienkiewicz, I. Cormeau. Arch. Mech. 24 (1972) 872.
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[16] Sri S. Kakarla ,Karim H.Muci-Kuchler, William J. Arbegast and
Casey D.Allen; Three-dimensional finite element model of the
friction stir spot welding process. (2005)
[17] Mokhtar Awang and Victor H.Mucino; Energy Generation during
Friction Stir Spot Welding (FSSW) of Al 6061-T6 Plates. (2010)
[18] Shigeki Hirasawa, Harsha Badarinarayan, Kazutaka Okamoto,
Toshio Tomimura, Tsuyoshi Kawanami; Analysis of effect of tool
geometry on plastic flow during friction stir spot welding using
particle method. (2010)
[19] Pierluigi Fanelli, Francesco Vivio, Vincenzo Vullo; Experimental
and numerical characterization of Friction Stir Spot Welded joints.
(2012)
[20] K. Colligan. Weld. J. 78 (1999) 229.
[21] A.Schey. Introduction to Manufacturing Processes
[22] R. Nandan, G. Roy, and T. Debroy. Metall. Mater. Trans. A 37 A
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(2007) 883.

51

[24] B. Liechty, B. Webb

Modeling the frictional boundary condition in friction stir
welding.(2008)
[25]
(2010)
[26]
(2011)
[27] R. T. Lee, C. T. Liu, and Y. C. Chiou, J. Chin. Soc. Mech. Eng., in
press.

52