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<p>Friction Stir welding (FSW) of particle-strengthened magnesium composites (AZ31 + 10%Si<sub>3</sub>N<sub>4</sub>) employing different tool pin profiles (TPP) hexagonal (HTPP), pentagonal (PTPP), and triangular (TTPP) using Abaqus software for life cycle evaluation is described in this work. The physical and thermo-mechanical simulations are detailed using a temperature-dependent elastoplastic material model. As FSW progresses, the silicon nitride (Si<sub>3</sub>N<sub>4</sub>) particles in AZ31 matrix move into the weldment area, where they increase strength via the formation of precipitates. The HTPP outperforms the PTPP (1250&#xa0;W/m<sup>2</sup>, 542&#xa0;°C, 5.961&#xa0;MPa) and triangular (1168&#xa0;W/m<sup>2</sup>, 534&#xa0;°C, 5.475&#xa0;MPa) geometries in terms of heat flow (1647&#xa0;W/m<sup>2</sup>), nodal temperature (585&#xa0;°C), and von-Mises stress (7.141&#xa0;MPa) among the designs that were experimentally studied. The HTPP achieves the best dynamic recrystallization (DRX), leading to the tiniest grain size (5.2&#xa0;μm) in the nugget zone with a consistent equiaxed shape, even though it has a small peak contact pressure (63&#xa0;MPa) and heat due to friction (3500&#xa0;W). Correlating with full DRX and almost random crystallographic texture, the hexagonal profile reaches the maximum Z value, according to the Zener-Hollomon parameter study. Across the weld zone, microhardness imaging shows a consistent range of 99.7-100.2 VHN for HTPP, but PTPP shows wider variability of 99.5-100.25 VHN and TTPP shows increased localized hard zones of 109-111.3 VHN. Microscopy and Voronoi grain mapping both show that the hexagonal TPP has more uniform and refined grains.</p>

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Friction stir welding of an AZ31-silicon nitride magnesium composite: finite element simulation approach

  • 期刊论文

  • 发表日期：

    2026年5月23日

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  • Pon Azhagiri,
  • M. Kumaresan,
  • C. K. Dhinakarraj,
  • A. Thanikasalam,
  • B. Deepanraj,
  • N. Senthilkumar

摘要

Friction Stir welding (FSW) of particle-strengthened magnesium composites (AZ31 + 10%Si3N4) employing different tool pin profiles (TPP) hexagonal (HTPP), pentagonal (PTPP), and triangular (TTPP) using Abaqus software for life cycle evaluation is described in this work. The physical and thermo-mechanical simulations are detailed using a temperature-dependent elastoplastic material model. As FSW progresses, the silicon nitride (Si3N4) particles in AZ31 matrix move into the weldment area, where they increase strength via the formation of precipitates. The HTPP outperforms the PTPP (1250 W/m2, 542 °C, 5.961 MPa) and triangular (1168 W/m2, 534 °C, 5.475 MPa) geometries in terms of heat flow (1647 W/m2), nodal temperature (585 °C), and von-Mises stress (7.141 MPa) among the designs that were experimentally studied. The HTPP achieves the best dynamic recrystallization (DRX), leading to the tiniest grain size (5.2 μm) in the nugget zone with a consistent equiaxed shape, even though it has a small peak contact pressure (63 MPa) and heat due to friction (3500 W). Correlating with full DRX and almost random crystallographic texture, the hexagonal profile reaches the maximum Z value, according to the Zener-Hollomon parameter study. Across the weld zone, microhardness imaging shows a consistent range of 99.7-100.2 VHN for HTPP, but PTPP shows wider variability of 99.5-100.25 VHN and TTPP shows increased localized hard zones of 109-111.3 VHN. Microscopy and Voronoi grain mapping both show that the hexagonal TPP has more uniform and refined grains.