Modelling and visualisation of material flow in friction stir spot welding

Abstract The material flow in friction stir spot welding of aluminium to both aluminium and steel has been investigated, using pinless tools in a lap joint geometry. The flow behaviour was revealed experimentally using dissimilar Al alloys of similar strength. The effect on the material flow of tool surface features, welding conditions (rotation speed, plunge depth, dwell time), and the surface state of the steel sheet (un-coated or galvanized) have been systematically studied. A novel kinematic flow model is presented, which successfully predicts the observed layering of the dissimilar Al alloys under a range of conditions. The model and the experimental observations provide a consistent interpretation of the stick-slip conditions at the tool-workpiece interface, addressing an elusive and long-standing issue in the modelling of heat generation in friction stir processing.

Design Optimisation for Compression Moulded Sheet Moulded Compounds

This paper builds on previous work to show how using holistic and iterative design optimisation tools can be used to produce a commercially viable product that reduces a costly assembly into a single moulded structure. An assembly consisting of a structural metallic support and compression moulding outer shell undergo design optimisation and analysis to remove the support from the assembly process in favour of a structural moulding. The support is analysed and a sheet moulded compound (SMC) alternative is presented, this is then combined into a manufacturable shell design which is then assessed on viability as an alternative to the original.
Alongside this a robust material selection system is implemented that removes user bias towards materials for designs. This system builds on work set out by the Cambridge Material Selector and Boothroyd and Dewhurst, while using a selection of applicable materials currently available for the compression moulding process. This material selection process has been linked into the design and analysis stage, via scripts for use in the finite element environment. This builds towards an analysis toolkit that is suggested to develop and enhance manufacturability of design studies.