The widespread application of thermoplastic polymers in different aspects of industries has motivated researchers and companies to improve and upgrade their forming, joining and assembling processes to overcome their limitations. One of the newest joining methods of thermoplastics is friction stir welding which is based on frictional heat generated through contact between a rotating tool and th...

The current paper presents a robust optimum design of friction stir welding (FSW) lap joint AA1100 aluminum alloy sheets using Monte Carlo simulation, NSGA-II and neural network. First, to find the relation between the inputs and outputs a perceptron neural network model was obtained. In this way, results of thirty friction stir welding tests are used for training and testing the neural network...

Friction stir welding is a refreshing approach to the joining of metals. Although originally intended for aluminium alloys, reach of FSW has now extended to a variety of materials including steels and polymers. This review deals with the fundamental understanding of the process and its metallurgical consequences. The focus is on heat generation, heat transfer and plastic flow during welding, el...

The objective of this study was to develop a numerical model for the prediction of temperature distribution, effective plastic strain distribution, and especially material flow in friction stir welding of copper plates. The DEFORM-3D software was used by incorporating a lagrangian incremental formulation. Threedimensional results of the material flow pattern which were extracted using the po...

This work deals with the modeling of the material flow in Friction Stir Welding (FSW) processes using particle tracing method. For the computation of particle trajectories, three accurate and computationally efficient integration methods are implemented within a FE model for FSW process: the Backward Euler with Substepping (BES), the 4-th order Runge-Kutta (RK4) and the Back and Forth Error Com...

A three-dimensional heat transfer model for friction stir welding (FSW) is presented in this paper; a moving coordinate is introduced to reduce the difficulty of modeling the moving tool. Heat input from the tool shoulder and the tool pin are considered in the model. The finite difference method was applied in solving the control equations. A non-uniform grid mesh is generated for the calculati...

The axial force measurement plays important role in tool designing and identification of its restrictions. Also, it is vital in design of machine mechanism and optimization of welding process parameters. In this study, a friction stir welded butt join on AA7075-T651 aluminum alloy plate is investigated. With change of some parameters, factors including axial force, mechanical properties, microh...

Metal Matrix Composites (MMCs) consist of a metal alloy reinforced with ceramic particles or fibers. These materials possess a very high strength to weight ratio, good resistance to impact and wear, and a number of other properties which make them attractive for use in aerospace and defense applications. MMCs have found use in the space shuttle orbiter's structural tubing, the Hubble Space Tele...