Impact of FSP Tool Probe Shape on Reinforcing Particles Dispersion in the Piston Alloy Using CEL Approach

الموضوعات :

Mostafa Akbari ¹ (Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran)
Hossein Rahimi Asiabaraki ² (Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran)
Ezatollah Hassanzadeh ³ (Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran)

تاريخ الإرسال : 30 السبت , جمادى الأولى, 1444 تاريخ التأكيد : 08 الإثنين , رجب, 1444 تاريخ الإصدار : 08 الإثنين , رجب, 1444

الکلمات المفتاحية: Composite, Hardness, Particle distribution, Microstructural, CEL Method,

ملخص المقالة :

In this study, the distribution of boron carbide in the stir zone of the FSPed specimens was examined experimentally and numerically about probe shape, including circular, square, and hexagonal shapes. First, composites were created using different tools. Then, using an optical microscope, the microstructural properties of the samples, such as the size and shape of the silicon particles, were examined. To simulate the procedure and further explore particle distribution, the coupled Eulerian-Lagrangian (CEL) method is employed. The tool was also modeled using a Lagrangian formulation while the material was characterized using an Eulerian formulation. The model predicted the changes in strain and temperature in composites created with different probe shapes. The outcome demonstrated that the circular probe was not suitable for the production of composites because it could not disperse particles in the parent alloy. Tools with flat surfaces, such as square and hexagonal tools, have more evenly distributed metal particles. Square probes can be employed in the FSP process to create composites and offer the best performance in terms of reinforcing particle distribution in the metal matrix. Due to the greater distribution of reinforcing particles, the sample made with a square tool had the highest hardness. Using a tool with a square pin improves the average hardness by 8 and 21%, respectively, compared to hexagonal and circular tools.

المصادر:

[1] Yadegari, H., Taherian, R. and Dariushi, S. 2021. Investigation on mechanical properties of hybrid aluminum/composite tubes manufactured by filament winding and hand lay-up.  Polymers and Polymer Composites. 29(9_suppl): S1486-S1497.

[2] Rajendran, C., Srinivasan, K., Balasubramanian, V., Balaji, H. and Selvaraj, P. 2021. Feasibility study of fsw, lbw and tig joining process to fabricate light combat aircraft structure.  International Journal of Lightweight Materials and Manufacture. 4(4): 480-490.

[3] Fathi, J., Ebrahimzadeh, P., Farasati, R. and Teimouri, R. 2019. Friction stir welding of aluminum 6061-t6 in presence of watercooling: Analyzing mechanical properties and residual stress distribution.  International Journal of Lightweight Materials and Manufacture. 2(2): 107-115.

[4] Akbari, M., Asadi, P. and Rahimi Asiabaraki, H. 2021. Improving the hardness and microstructural properties of piston alloy using the fsp method.  Journal of Modern Processes in Manufacturing and Production. 10(2): 53-62.

[5] Zolghadr, P., Akbari, M. and Asadi, P. 2019. Formation of thermo-mechanically affected zone in friction stir welding.  Materials Research Express. 6(8): 086558.

[6] Afsari, A., Heidari, S. and Jafari, J. 2020. Evaluation of optimal conditions, microstructure, and mechanical properties of aluminum to copper joints welded by fsw.  Journal of Modern Processes in Manufacturing and Production. 9(4): 61-81.

[7] Rezaee Hajideh, M., Farahani, M. and Khanbeigi, M.A. 2017. A hybrid thermal assisted friction stir welding approach for pmma sheets.  Journal of Modern Processes in Manufacturing and Production. 6(2): 51-60.

[8] Shojaeefard, M.H., Akbari, M., Asadi, P. and Khalkhali, A. 2016. The effect of reinforcement type on the microstructure, mechanical properties, and wear resistance of a356 matrix composites produced by fsp.  The International Journal of Advanced Manufacturing Technology.): 1-17.

[9] Akbari, M., Asadi, P., Besharati Givi, M.K. and Khodabandehlouie, G. 2014. Artificial neural network and optimization, in Advances in Friction-Stir Welding and Processing, Woodhead Publishing, Elsevier.

[10] Sharma, A., Fujii, H. and Paul, J. 2020. Influence of reinforcement incorporation approach on mechanical and tribological properties of aa6061- cnt nanocomposite fabricated via fsp.  Journal of Manufacturing Processes. 59: 604-620.

[11] Darzi Bourkhani, R., Eivani, A.R., Nateghi, H.R. and Jafarian, H.R. 2020. Effects of pin diameter and number of cycles on microstructure and tensile properties of friction stir fabricated aa1050-al2o3 nanocomposite.  Journal of Materials Research and Technology. 9(3): 4506-4517.

[12] Li, S., Paidar, M., Liu, S., Mehrez, S., Kumar, P.S. and Mohanavel, V. 2022. Importance of pin number on mechanical properties and wear performance during manufacturing of aa6061/316 surface composite via fsp.  Materials Letters. 326: 132919.

[13] Sarvaiya, J. and Singh, D. 2022. Influence of hybrid pin profile on enhancing microstructure and mechanical properties of aa5052/sic surface composites fabricated via friction stir processing.  The Canadian Journal of Metallurgy and Materials Science. 1-14: https://doi.org/10.1080/00084433.2022.2114124.

[14] Asadi, P., Akbari, M. and Karimi-Nemch, H.  2014. Simulation of friction stir welding and processing, Advances in Friction-Stir Welding and Processing. Woodhead Publishing, Elsevier.

[15] Akbari, M., Asadi, P. and Behnagh, R.A. 2021. Modeling of material flow in dissimilar friction stir lap welding of aluminum and brass using coupled eulerian and lagrangian method.  The International Journal of Advanced Manufacturing Technology. 113(3): 721-734.

[16] Mohammadi Kuhbanani, H., Yasemi, H. and Aghajani Derazkola, H. 2018. Effects of tool tilt angle and plunge depth on properties of polycarbonate fsw joint.  Journal of Modern Processes in Manufacturing and Production. 7(4): 41-55.

[17] Asadi, P., Mirzaei, M. and Akbari, M. 2022. Modeling of pin shape effects in bobbin tool fsw.  International Journal of Lightweight Materials and Manufacture. 5(2): 162-177.

[18] Akbari, M. and Asadi, P. 2021. Simulation and experimental investigation of multi-walled carbon nanotubes/aluminum composite fabrication using friction stir processing.  Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering. 235(6): 2165-2179.

[19] Grujicic, M., Snipes, J.S., Ramaswami, S., Galgalikar, R., Yen, C.F. and Cheeseman, B.A. 2017. Computational analysis of the intermetallic formation during the dissimilar metal aluminum-to-steel friction stir welding process.  Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 233(6): 1080-1100.

[20] Chu, Q., Yang, X.W., Li, W.Y., Vairis, A. and Wang, W.B. 2018. Numerical analysis of material flow in the probeless friction stir spot welding based on coupled eulerian-lagrangian approach.  Journal of Manufacturing Processes. 36: 181-187.

[21] Akbari, M. and Asadi, P. 2021. Optimization of microstructural and mechanical properties of brass wire produced by friction stir extrusion using taguchi method.  Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 235(12): 2709-2719.

[22] Al-Badour, F., Merah, N., Shuaib, A. and Bazoune, A. 2013. Coupled eulerian lagrangian finite element modeling of friction stir welding processes.  Journal of Materials Processing Technology. 213(8): 1433-1439.

[23] Akbari, M. and Asadi, P. 2020. Dissimilar friction stir lap welding of aluminum to brass: Modeling of material mixing using coupled eulerian–lagrangian method with experimental verifications.  Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 234(8): 1117-1128.

[24] Das, D., Bag, S. and Pal, S. 2021. A finite element model for surface and volumetric defects in the fsw process using a coupled eulerian–lagrangian approach.  Science and Technology of Welding and Joining. 26(5): 412-419.

[25] Ragab, M., Liu, H., Yang, G. J. and Ahmed, M.M.Z. 2021. Friction stir welding of 1cr11ni2w2mov martensitic stainless steel: Numerical simulation based on coupled eulerian lagrangian approach supported with experimental work.  Applied Sciences. 11(7): 3049.

[26] Alidokht, S.A., Abdollah-zadeh, A., Soleymani, S., Saeid, T. and Assadi, H. 2012. Evaluation of microstructure and wear behavior of friction stir processed cast aluminum alloy.  Materials Characterization. 63: 90-97.

[27] Heidarzadeh, A., Kazemi-Choobi, K., Hanifian, H. and Asadi, P. 2014. Microstructural evolution, Advances in Friction-Stir Welding and Processing. Woodhead Publishing, Elsevier.

[28] Marzbanrad, J., Akbari, M., Asadi, P. and Safaee, S. 2014. Characterization of the influence of tool pin profile on microstructural and mechanical properties of friction stir welding Metallurgical and Materials Transactions B. 45:1887–1894.

[29] Shinoda, T. and Kawai, M. 2003. Surface modification by novel friction thermomechanical process of aluminum alloy castings.  Surface and Coatings Technology. 169–170: 456-459.

[30] Dolatkhah, A., Golbabaei, P., Besharati Givi, M.K. and Molaiekiya, F. 2012. Investigating effects of process parameters on microstructural and mechanical properties of al5052/sic metal matrix composite fabricated via friction stir processing.  Materials & Design. 37: 458-464.

[31] Shafiei-Zarghani, A., Kashani-Bozorg, S.F. and Zarei-Hanzaki, A. 2009. Microstructures and mechanical properties of al/al2o3 surface nano-composite layer produced by friction stir processing.  Materials Science and Engineering: A. 500(1–2): 84-91.