Submit to Materials Review for Materials Propose a Special Issue

Journal Browser

Effect of Hot Manufacturing Methods on Material Processing by Finite Element Modelling

Print Special Issue Flyer
Special Issue Editors
Special Issue Information
Keywords
Published Papers

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (10 December 2022) | Viewed by 18531

Share This Special Issue

Special Issue Editors

Dr. Eduardo Garcia

E-Mail Website
Guest Editor

Department of Mechanics, Design and Industrial Management, University of Deusto, 48007 Bilbao, Spain
Interests: manufacturing process; hot forming; material modelling; microstructure simulation; tube forming; friction and wear; precision machining

Dr. Alberto Murillo-Marrodán

E-Mail Website
Guest Editor

Department of Mechanics, Design and Industrial Management, University of Deusto, Avda Universidades 24, 48007 Bilbao, Spain
Interests: metal forming; constitutive modelling; material characterization; finite element analysis microstructural evolution

Dr. Hamed Aghajani Derazkola

E-Mail Website
Guest Editor

Department of Mechanics, Design and Industrial Management, University of Deusto, 48007 Bilbao, Spain
Interests: finite element analysis; monte carlo modelling; cellular automaton modelling; computational fluid dynamic modelling; solid-state joining; solid-state additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Despite scientific and practical advances in the science of manufacturing processes, many issues in this field are still not well understood. One of the industrial and research branches in this field is thermomechanical (TM) processes. With the TM method, final materials or products can be produced with targeted mechanical, chemical, thermal, electrical or metallurgical properties. With the TM process, the properties of the raw material can be greatly improved. Accordingly, the development of TM production processes or the use of new materials and products with this method are still developing and will have a bright future. Various types of production methods are performed with the TM process, including forming, welding, microstructural changes to produce nanostructures in bulk materials, as well as additive manufacturing. Stress, heat transfer, strain, strain rate, phase transformations, changes in microstructure, and changes in material state and properties are examples of fundamental topics that can be studied around TM process development for the use of new materials with TM processes. These factors make the simulation and computational and numerical modeling of TM manufacturing processing very challenging.

Therefore, the aim of this Special Issue is to publish new and novel research focusing on simulation, modeling, and computational methods of TM processes and materials behavior during TM processes. Testing of all classes of materials during TM manufacturing from atomistic to macroscopic length scales (structure–property relationships) are welcome. Constitutive, Monte Carlo, and cellular automaton modeling with verification is of interest as well.

Papers on the utilization of various numerical methods to simulate TM manufacturing processes such as solid-state joining, solid-state additive manufacturing, thermomechanical properties of additive manufacturing parts, forging, hot forming, ECAP, etc. are especially welcome.

Dr. Eduardo Garcia
Dr. Alberto Murillo-Marrodán
Dr. Hamed Aghajani Derazkola
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

thermomechanical process simulations
material modeling in thermomechanical condition
solid-state joining simulation
solid-state additive manufacturing simulation
backward and forward hot extrusion simulation
hot forging simulation
hot rolling simulation
hot piercing simulation
hot sheet metal forming simulation
high strain hot forming simulation
thermomechanical manufacturing development

Published Papers (7 papers)

Download All Papers

Research

15 pages, 4575 KiB

Open AccessArticle

Effect of Tool Positioning Factors on the Strength of Dissimilar Friction Stir Welded Joints of AA7075-T6 and AA6061-T6

by Amir Ghiasvand, Saja Mohammed Noori, Wanich Suksatan, Jacek Tomków, Shabbir Memon and Hesamoddin Aghajani Derazkola

Materials 2022, 15(7), 2463; https://doi.org/10.3390/ma15072463 - 27 Mar 2022

Cited by 8 | Viewed by 1754

Abstract

Friction Stir Welding (FSW) is a solid-state bonding technique. There are many direct and indirect factors affecting the mechanical and microstructural properties of the FSW joints. Tool offset, tilt angle, and plunge depth are determinative tool positioning in the FSW process. Investigating the effect of these factors simultaneously with other parameters such as process speeds (rotational speed and translational speed) and tool geometry leads to a poor understanding of the impact of these factors on the FSW process. Because the three mentioned parameters have the same origin, they should be studied separately from other process parameters. This paper investigates the effects of tilt angle, plunge depth, and tool offset on Ultimate Tensile Stress (UTS) of joints between AA6061-T6 and AA7075-T6. To design the experiments, optimization, and statistical analysis, Response Surface Methodology (RSM) has been used. Experimental tests were carried out to find the maximum achievable UTS of the joint. The optimum values were determined based on the optimization procedure as 0.7 mm of tool offset, 2.7 degrees of tilt angle, and 0.1 mm of plunge depth. These values resulted in a UTS of 281 MPa. Compared to the UTS of base metals, the joint efficiency of the optimized welded sample was nearly 90 percent. Full article

(This article belongs to the Special Issue Effect of Hot Manufacturing Methods on Material Processing by Finite Element Modelling)

► Show Figures

Figure 1

17 pages, 4053 KiB

Open AccessArticle

Investigation of the Effects of Tool Positioning Factors on Peak Temperature in Dissimilar Friction Stir Welding of AA6061-T6 and AA7075-T6 Aluminum Alloys

by Amir Ghiasvand, Wanich Suksatan, Jacek Tomków, Grzegorz Rogalski and Hesamoddin Aghajani Derazkola

Materials 2022, 15(3), 702; https://doi.org/10.3390/ma15030702 - 18 Jan 2022

Cited by 16 | Viewed by 2065

Abstract

Among the emerging new welding techniques, friction stir welding (FSW) is used frequently for welding high-strength aluminum alloys that are difficult to weld by conventional fusion-welding techniques. This paper investigated the effects of tool-positioning factors on the maximum temperature generated in the dissimilar FSW joint of AA6061-T6 and AA7075-T6 aluminum alloys. Three factors of plunge depth, tool offset, and tilt angle were used as the input parameters. Numerical simulation of the FSW process was performed in ABAQUS software using the coupled Eulerian–Lagrangian (CEL) approach. Central composite design (CCD) based on response surface methodology (RSM) was used to analyze and design the experiments. Comparison of the numerical and experimental results showed that numerical simulations were in good agreement with the experimental ones. Based on the statistical model results, plunge depth, tilt angle, and tool offset were the most significant factors on maximum process temperature, respectively. It was found that increasing the plunge depth caused a sharp increase in the maximum process temperature due to increased contact surfaces and the frictional interaction between the tool and workpiece. Full article

(This article belongs to the Special Issue Effect of Hot Manufacturing Methods on Material Processing by Finite Element Modelling)

► Show Figures

Figure 1

13 pages, 5452 KiB

Open AccessArticle

Pin Angle Thermal Effects on Friction Stir Welding of AA5058 Aluminum Alloy: CFD Simulation and Experimental Validation

by Supat Chupradit, Dmitry Olegovich Bokov, Wanich Suksatan, Michał Landowski, Dariusz Fydrych, Mahmoud E. Abdullah and Hesamoddin Aghajani Derazkola

Materials 2021, 14(24), 7565; https://doi.org/10.3390/ma14247565 - 9 Dec 2021

Cited by 20 | Viewed by 2927

Abstract

The friction stir welding (FSW) of tool pin geometry plays a critical role in the final properties of the produced joint. The tool pin geometry directly affects the generation of heat and the flow of internal materials during the FSW process. The effects of the FSW tool pin angle on heat generation and internal flow have not been quantitatively investigated in detail. In this manuscript, a validated Computational Fluid Dynamic (CFD) model was implemented to analyze the effects of pin angle on the thermo-mechanical action during the FSW process of AA5058 Al-Mg alloy. Experimental test results validate the thermal outcomes of the used model. The obtained results revealed that, when the pin angle is increased, the heat generation decreases while the mechanical action of the tool increases. The internal heat distribution at a higher pin angle is symmetrical. The higher mechanical action of the tool decreases the viscosity of the internal materials and increases stirring action (materials flow) around the pin. Furthermore, plastic flow near the tool increased stirring action and formed a larger stir zone in the joint area. Full article

(This article belongs to the Special Issue Effect of Hot Manufacturing Methods on Material Processing by Finite Element Modelling)

► Show Figures

Figure 1

19 pages, 7349 KiB

Open AccessArticle

Investigation of Mechanical and Microstructural Properties of Welded Specimens of AA6061-T6 Alloy with Friction Stir Welding and Parallel-Friction Stir Welding Methods

by Amir Ghiasvand, Mohammad Mahdi Yavari, Jacek Tomków, John William Grimaldo Guerrero, Hasan Kheradmandan, Aleksei Dorofeev, Shabbir Memon and Hesamoddin Aghajani Derazkola

Materials 2021, 14(20), 6003; https://doi.org/10.3390/ma14206003 - 12 Oct 2021

Cited by 18 | Viewed by 2305

Abstract

The present study investigates the effect of two parameters of process type and tool offset on tensile, microhardness, and microstructure properties of AA6061-T6 aluminum alloy joints. Three methods of Friction Stir Welding (FSW), Advancing Parallel-Friction Stir Welding (AP-FSW), and Retreating Parallel-Friction Stir Welding (RP-FSW) were used. In addition, four modes of 0.5, 1, 1.5, and 2 mm of tool offset were used in two welding passes in AP-FSW and RP-FSW processes. Based on the results, it was found that the mechanical properties of welded specimens with AP-FSW and RP-FSW techniques experience significant increments compared to FSW specimens. The best mechanical and microstructural properties were observed in the samples welded by RP-FSW, AP-FSW, and FSW methods, respectively. Welded specimens with the RP-FSW technique had better mechanical properties than other specimens due to the concentration of material flow in the weld nugget and proper microstructure refinement. In both AP-FSW and RP-FSW processes, by increasing the tool offset to 1.5 mm, joint efficiency increased significantly. The highest weld strength was found for welded specimens by RP-FSW and AP-FSW processes with a 1.5 mm tool offset. The peak sample of the RP-FSW process (1.5 mm offset) had the closest mechanical properties to the base metal, in which the Yield Stress (YS), ultimate tensile strength (UTS), and elongation percentage (E%) were 76.4%, 86.5%, and 70% of base metal, respectively. In the welding area, RP-FSW specimens had smaller average grain size and higher hardness values than AP-FSW specimens. Full article

(This article belongs to the Special Issue Effect of Hot Manufacturing Methods on Material Processing by Finite Element Modelling)

► Show Figures

Figure 1

17 pages, 9482 KiB

Open AccessArticle

Thermo-Mechanical Simulation of Underwater Friction Stir Welding of Low Carbon Steel

by Shabbir Memon, Jacek Tomków and Hesamoddin Aghajani Derazkola

Materials 2021, 14(17), 4953; https://doi.org/10.3390/ma14174953 - 30 Aug 2021

Cited by 23 | Viewed by 2368

Abstract

This article investigates the flow of materials and weld formation during underwater friction stir welding (UFSW) of low carbon steel. A thermo-mechanical model is used to understand the relation between frictional heat phenomena during the welding and weld properties. To better understand the effects of the water environment, the simulation and experimental results were compared with the sample prepared by the traditional friction stir welding (FSW) method. Simulation results from surface heat diffusion indicate a smaller preheated area in front of the FSW tool declined the total generated heat in the UFSWed case compared to the FSWed sample. The simulation results revealed that the strain rate of steel in the stir zone (SZ) of the FSWed joint is higher than in the UFSWed case. The microstructure of the welded sample shows that SZ’s microstructure at the UFSWed case is more refined than the FSWed case due to the higher cooling rate of the water environment. Due to obtained results, the maximum temperatures of FSWed and UFSWed cases were 1228 °C and 1008 °C. Meanwhile, the simulation results show 1200 °C and 970 °C for conventional and underwater FSW samples, respectively. The maximum material velocity in SZ predicted 0.40 m/s and 0.32 m/s for FSW and underwater FSWed samples. The better condition in the UFSW case caused the ultimate tensile strength of welded sample to increase ~20% compared to the FSW joint. Full article

(This article belongs to the Special Issue Effect of Hot Manufacturing Methods on Material Processing by Finite Element Modelling)

► Show Figures

Figure 1

17 pages, 5357 KiB

Open AccessArticle

Effects of FSW Tool Plunge Depth on Properties of an Al-Mg-Si Alloy T-Joint: Thermomechanical Modeling and Experimental Evaluation

by Shabbir Memon, Dariusz Fydrych, Aintzane Conde Fernandez, Hamed Aghajani Derazkola and Hesamoddin Aghajani Derazkola

Materials 2021, 14(16), 4754; https://doi.org/10.3390/ma14164754 - 23 Aug 2021

Cited by 33 | Viewed by 3421

Abstract

One of the main challenging issues in friction stir welding (FSW) of stiffened structures is maximizing skin and flange mixing. Among the various parameters in FSW that can affect the quality of mixing between skin and flange is tool plunge depth (TPD). In this research, the effects of TPD during FSW of an Al-Mg-Si alloy T-joint are investigated. The computational fluid dynamics (CFD) method can help understand TPD effects on FSW of the T-joint structure. For this reason, the CFD method is employed in the simulation of heat generation, heat distribution, material flow, and defect formation during welding processes at various TPD. CFD is a powerful method that can simulate phenomena during the mixing of flange and skin that are hard to assess experimentally. For the evaluation of FSW joints, macrostructure visualization is carried out. Simulation results showed that at higher TPD, more frictional heat is generated and causes the formation of a bigger stir zone. The temperature distribution is antisymmetric to the welding line, and the concentration of heat on the advancing side (AS) is more than the retreating side (RS). Simulation results from viscosity changes and material velocity study on the stir zone indicated that the possibility of the formation of a tunnel defect on the skin–flange interface at the RS is very high. Material flow and defect formation are very sensitive to TPD. Low TPD creates internal defects with incomplete mixing of skin and flange, and high TPD forms surface flash. Higher TPD increases frictional heat and axial force that diminish the mixing of skin and flange in this joint. The optimum TPD was selected due to the best materials flow and final mechanical properties of joints. Full article

(This article belongs to the Special Issue Effect of Hot Manufacturing Methods on Material Processing by Finite Element Modelling)

► Show Figures

Figure 1

18 pages, 9550 KiB

Open AccessArticle

Analysis of Friction Stir Welding Tool Offset on the Bonding and Properties of Al–Mg–Si Alloy T-Joints

by Shabbir Memon, Alberto Murillo-Marrodán, Hamid M. Lankarani and Hesamoddin Aghajani Derazkola

Materials 2021, 14(13), 3604; https://doi.org/10.3390/ma14133604 - 28 Jun 2021

Cited by 30 | Viewed by 2681

Abstract

Research on T-configuration aluminum constructions effectively decreases fuel consumption, increases strength, and develops aerial structures. In this research, the effects of friction stir welding (FSW) tool offset (TO) on Al–Mg–Si alloy mixing and bonding in T-configurations is studied. The process is simulated by the computational fluid dynamic (CFD) technique to better understand the material mixing flow and the bonding between the skin and flange during FSW. According to the results, the best material flow can be only achieved at an appropriate TO. The appropriate TO generates enough material to fill the joint line and results in formation of the highest participation of the flange in the stir zone (SZ) area. The results show that, in the T-configuration, FSW joints provide raw materials from the retreating side (RS) of the flange that play a primary role in producing a sound mixing flow. The selected parameters were related to the geometric limitations of the raw sheets considered in this study. The failure point of all tensile samples was located on the flange. Surface tunneling is the primary defect in these joints, which is produced at high TOs. Among the analyzed cases, the most robust joint was made at +0.2 mm TO on the advancing side (AS), resulting in more than 60% strength of the base aluminum alloy being retained. Full article

(This article belongs to the Special Issue Effect of Hot Manufacturing Methods on Material Processing by Finite Element Modelling)

► Show Figures

Figure 1

Journal Menu

Journal Browser

Effect of Hot Manufacturing Methods on Material Processing by Finite Element Modelling

Share This Special Issue

Special Issue Editors

Special Issue Information

Keywords

Published Papers (7 papers)

Research

Further Information

Guidelines

MDPI Initiatives

Follow MDPI