Friction stir welding (FSW) is a widely used solid state joining process for soft materials such as aluminium alloys because it avoids many of the common problems of fusion welding. Commercial feasibility of the FSW process for harder alloys such as steels and titanium alloys awaits the development of cost effective and durable tools which lead to structurally sound welds consistently. Material selection and design profoundly affect the performance of tools, weld quality and cost. Here we review and critically examine several important aspects of FSW tools such as tool material selection, geometry and load bearing ability, mechanisms of tool degradation and process economics.

Review: friction stir welding tools

https://cyberleninka.org/article/n/403409.pdf

A review of numerical analysis of friction stir welding

Design decision support related to building energy consumption and / or indoor climate, should be based on an integral approach of environment, building, heating, ventilating and airconditioning (HVAC) system and occupants. The tools to achieve this are now available in the form of computer simulation systems which treat the building and plant as an integrated, dynamic system. Although its potentials reach beyond the area of Computer Aided Building Design, the paper describes building and plant energy simulation simulation within the context of CABD, design decision support and design evaluation. Currently, computer simulation is only used indirectly as a design decision support mechanism; ie its power is not delivered very efficiently to the design profession. Future research directions are indicated, aimed at providing a mechanism to overcome this problem by developing an "intelligent front end" which bridges the gap between sophisticated computer simulation tools and the design profession.

Energy simulation in building design

In Mechanics, material properties are most often regarded as being given, and based on this, many technical solutions are usually conceived and constructed. However, nowadays manufacturing processes have advanced to the point that metamaterials having selected properties can be designed and fabricated. Three-dimensional printing, electrospinning, self-assembly, and many other advanced manufacturing techniques are raising a number of scientific questions which must be addressed if the potential of these new technologies is to be fully realized. In this work, we report on the status of modeling and analysis of metamaterials exhibiting a rich and varied macroscopic response conferred by complex microstructures and particularly focus on strongly interacting inextensible or nearly inextensible fibers. The principal aim is to furnish a framework in which the mechanics of 3D rapid prototyping of microstructured lattices and fabrics can be clearly understood and exploited. Moreover, several-related open questions will be identified and discussed, and some methodological considerations of general interest are provided.

/pdf/synthesis-of-fibrous-complex-structures-designing-4dmwnghc7g.pdf

Synthesis of Fibrous Complex Structures: Designing Microstructure to Deliver Targeted Macroscale Response

Mechanical joining technologies are increasingly used in multi-material lightweight constructions and offer opportunities to create versatile joining processes due to their low heat input, robustness to metallurgical incompatibilities and various process variants. They can be categorised into technologies which require an auxiliary joining element, or do not require an auxiliary joining element. A typical example for a mechanical joining process with auxiliary joining element is self-piercing riveting. A wide range of processes exist which are not requiring an auxiliary joining element. This allows both point-shaped (e.g., by clinching) and line-shaped (e.g., friction stir welding) joints to be produced. In order to achieve versatile processes, challenges exist in particular in the creation of intervention possibilities in the process and the understanding and handling of materials that are difficult to join, such as fiber reinforced plastics (FRP) or high-strength metals. In addition, predictive capability is required, which in particular requires accurate process simulation. Finally, the processes must be measured non-destructively in order to generate control variables in the process or to investigate the cause-effect relationship. This paper covers the state of the art in scientific research concerning mechanical joining and discusses future challenges on the way to versatile mechanical joining processes. 

Review on mechanical joining by plastic deformation

https://strathprints.strath.ac.uk/5065/1/Mackenzie_D_Plastic_collapse_of_pipe_bends_under_combined_internal_pressure_and_in_plane_bending_May_2005.pdf

Plastic collapse of pipe bends under combined internal pressure and in-plane bending

Purpose – The friction stir welding (FSW) process comprises several highly coupled (and non‐linear) physical phenomena: large plastic deformation, material flow transportation, mechanical stirring of the tool, tool‐workpiece surface interaction, dynamic structural evolution, heat generation from friction and plastic deformation. This paper aims to present an advanced finite element (FE) model encapsulating this complex behaviour and various aspects associated with the FE model such as contact modelling, material model and meshing techniques are to be discussed in detail.Design/methodology/approach – The numerical model is continuum solid mechanics‐based, fully thermo‐mechanically coupled and has successfully simulated the FSW process including plunging, dwelling and welding stages.Findings – The development of several field variables are quantified by the model: temperature, stress, strain. Material movement is visualized by defining tracer particles at the locations of interest. The numerically computed ...

/pdf/multi-physics-simulation-of-friction-stir-welding-process-4rjan79z6z.pdf

Multi‐physics simulation of friction stir welding process

Purpose: The Friction Stir Welding (FSW) process comprises of several highly coupled (and non-linear) physical phenomena: large plastic deformation, material flow transportation, mechanical stirring of the tool, tool-workpiece surface interaction, dynamic structural evolution, heat generation from friction and plastic deformation, etc. In this paper, an advanced Finite Element (FE) model encapsulating this complex behavior is presented and various aspects associated with the FE model such as contact modeling, material model and meshing techniques are discussed in detail. Methodology: The numerical model is continuum solid mechanics-based, fully thermomechanically coupled and has successfully simulated the friction stir welding process including plunging, dwelling and welding stages. Findings: The development of several field variables are quantified by the model: temperature, stress, strain, etc. Material movement is visualized by defining tracer particles at the locations of interest. The numerically computed material flow patterns are in very good agreement with the general findings from experiments. Value: The model is, to the best of the authors’ knowledge, the most advanced simulation of FSW published in the literature.

Multi-physics simulation of friction stir welding process

https://strathprints.strath.ac.uk/5692/5/Mackenzie_D_Characterising_gross_plastic_deformation_in_design_by_analysis_Oct_2005.pdf

Characterising gross plastic deformation in design by analysis

The allowable plastic load in pressure vessel design by analysis is determined by applying a graphical construction to a characteristic load-deformation plot of the collapse behavior of the vessel. This paper presents an alternative approach to the problem. The plastic response is characterized by considering the curvature of a plot of plastic work dissipated in the vessel against the applied load. It is proposed that salient points of curvature correspond to critical stages in the evolution of the gross plastic deformation mechanism. In the proposed plastic work curvature (PWC) criterion of plastic collapse, the plastic load is defined as the load corresponding to zero or minimal plastic work curvature after yielding and the formation of plastic mechanisms have occurred. Application of the proposed criterion is illustrated by considering the elastic-plastic response of a simple cantilever beam in bending and a complex three-dimensional finite element analysis of a nozzle intersection. The results show that the proposed approach gives higher values of plastic load than alternative criteria when the material exhibits strain hardening. It is proposed that this is because the PWC criterion more fully represents the constraining effect of material strain hardening on the spread of plastic deformation.

/pdf/a-plastic-load-criterion-for-inelastic-design-by-analysis-4hb6gysdyx.pdf

A plastic load criterion for inelastic design by analysis

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