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<p>Friction stir welding (FSW) is a complex process that involves thermal-mechanical coupling and material flow. The evolution of the temperature field and the flow of plastic materials directly influence weld formation and joint quality. This paper aims to develop a high-precision numerical model to investigate the influence of key process parameters on the welding temperature field and material flow. Using the Coupled Euler-Lagrange (CEL) method, we introduce the temperature dependence of the friction coefficient for 6061-T6 aluminium alloy to create a thermomechanical coupled simulation model that accounts for the temperature effect on the friction coefficient. We simulate the effects of parameters such as stirring head rotation speed, welding travel speed, and shoulder downforce on the welding process. Thermocouple measurements indicate that the model accurately predicts peak temperature distributions. Increasing the rotation speed significantly raises the peak temperature and expands the heat-affected zone due to increased friction frequency. In contrast, welding speed and shoulder downforce primarily regulate the temperature distribution pattern. Proper control of rotation speed, welding travel speed, and shoulder downforce can optimise heat input distribution and enhance weld formation quality.</p>

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Simulation and experiment of friction stir welding on aluminium alloy considering temperature effect of friction coefficient

  • 期刊论文

  • 发表日期：

    2025年8月14日

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  • Yinglei Xue,
  • Bo Liu,
  • Huizhao Li,
  • Xuefeng Chao,
  • Songgang Zheng,
  • Dachao Xing

摘要

Friction stir welding (FSW) is a complex process that involves thermal-mechanical coupling and material flow. The evolution of the temperature field and the flow of plastic materials directly influence weld formation and joint quality. This paper aims to develop a high-precision numerical model to investigate the influence of key process parameters on the welding temperature field and material flow. Using the Coupled Euler-Lagrange (CEL) method, we introduce the temperature dependence of the friction coefficient for 6061-T6 aluminium alloy to create a thermomechanical coupled simulation model that accounts for the temperature effect on the friction coefficient. We simulate the effects of parameters such as stirring head rotation speed, welding travel speed, and shoulder downforce on the welding process. Thermocouple measurements indicate that the model accurately predicts peak temperature distributions. Increasing the rotation speed significantly raises the peak temperature and expands the heat-affected zone due to increased friction frequency. In contrast, welding speed and shoulder downforce primarily regulate the temperature distribution pattern. Proper control of rotation speed, welding travel speed, and shoulder downforce can optimise heat input distribution and enhance weld formation quality.