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On the Utility of the Thermal-Pseudo Mechanical Model’s Residual Stress Prediction Capability for the Development of Friction Stir Processing

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Abstract

This paper investigates the thermal-pseudo mechanical (TPM) model’s residual stress prediction capability for its utility in developing friction stir processing (FSP). Specifically, two FSP tests under different processing conditions were conducted, and the corresponding simulations were carried out to verify if the TPM model can predict residual stresses for various tool radii and workpiece materials. The model successfully predicted residual stresses with an error less than 4% for one of the tests but failed to work for the other test. Further simulations under different FSP conditions proved that the TPM model works for cast aluminum alloys and wrought aluminum alloys. In addition, the large FSP tool used was found to be the reason for the model’s failure on one of the tests. This indicates that there is a range of tool radii for which the TPM model is applicable. As a solution, this paper suggests modifications to the TPM model based on calibration to the FSP test temperatures. The resulting residual stress prediction is accurate and differs from the experimentally characterized stress values by only 6.5 MPa. The calibrated TPM model requires FSP to be carried out when using a tool with a different radius. Following that, the effect on residual stresses due to changes in the other process parameters, such as the tool traverse & rotation speeds and the clamping conditions, can be predicted.

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Funding

The authors acknowledge the role of funding from the Department of Energy’s Vehicle Technology Office under the Lightweight Metals Core Program. The role of Stresstech Ltd. in performing the residual stress measurements is also acknowledged.

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Authors and Affiliations

  1. Pacific Northwest National Laboratory, Richland, WA, 99354, USA

    Kranthi Balusu, Kyoo Sil Choi, Hrishikesh Das, Avik Samanta, Piyush Upadhyay, Saumyadeep Jana & Ayoub Soulami

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  1. Kranthi Balusu
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Contributions

Kranthi Balusu: Conceptualization, Writing—Original Draft, Methodology, Software, Validation, Visualization, Investigation. Kyoo Sil Choi: Writing—Review & Editing, Methodology. Hrishikesh Das, Avik Samanta: Writing—Review & Editing, Methodology, Visualization, Investigation. Piyush Upadhyay, Saumyadeep Jana: Funding acquisition, Supervision, Resources. Ayoub Soulami: Conceptualization, Funding acquisition, Supervision, Project administration.

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Appendices

Appendix A. Parameters for the Myhr & Grong Softening Model

Table 3 here

Table 3 Softening model parameters used for A7075 alloy
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Appendix B. Material Properties for A7075 and A380 Alloys

Table 4 here

Table 4 Temperature-dependent yield stresses of aluminum alloy A7075 [47, 48] and A380 [49]
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Table 5 here

Table 5 Other temperature-dependent properties of the aluminum alloys [47]
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Balusu, K., Choi, K.S., Das, H. et al. On the Utility of the Thermal-Pseudo Mechanical Model’s Residual Stress Prediction Capability for the Development of Friction Stir Processing. Int J Adv Manuf Technol 126, 1775–1788 (2023). https://doi.org/10.1007/s00170-023-11199-2

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