<p>Maraging steel, known for its high tensile strength and fracture toughness, is crucial in high-performance aerospace applications like airplane landing gear, helicopter undercarriages, and rocket engine casings. FSW, a solid-state joining procedure, is frequently utilized for softer materials, including aluminum, magnesium, and zinc. Its efficacy has generated interest in using FSW in steel and titanium alloys. High strength and heat generation make welding maraging steel problematic and affect deformation, residual stresses, and joint stability. This study employs Comsol Multiphysics to conduct a transient heat transfer analysis of FSW in maraging steel, focusing on understanding heat distribution and predicting peak temperature obtained in the workpiece under different rotational speeds and welding speeds. The simulation analyzes the peak temperature obtained during FSW of maraging steel at various tool rotational speeds (TRS: 50–250 rpm) and welding speeds (WS: 10–50 mm/min). The findings indicate that when TRS increases, the peak temperature increases, whereas increasing WS causes the peak temperature to decrease. TRS is recognized as the most significant factor determining thermal input. The numerical model has been evaluated using Response Surface Methodology (RSM), resulting in outstanding statistical agreement (<InlineEquation ID="IEq1"> <EquationSource Format="TEX">$R^{2} = 99.99\%$</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <msup> <mi>R</mi> <mn>2</mn> </msup> <mo>=</mo> <mn>99.99</mn> <mo>%</mo> </mrow> </math></EquationSource> </InlineEquation>, adjusted <InlineEquation ID="IEq2"> <EquationSource Format="TEX">$R^{2} = 99.97\%$</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <msup> <mi>R</mi> <mn>2</mn> </msup> <mo>=</mo> <mn>99.97</mn> <mo>%</mo> </mrow> </math></EquationSource> </InlineEquation>, projected <InlineEquation ID="IEq3"> <EquationSource Format="TEX">$R^{2} = 99.86\%$</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <msup> <mi>R</mi> <mn>2</mn> </msup> <mo>=</mo> <mn>99.86</mn> <mo>%</mo> </mrow> </math></EquationSource> </InlineEquation>). Tool rotational speed (TRS) exhibited the greatest impact, as confirmed by ANOVA (<InlineEquation ID="IEq4"> <EquationSource Format="TEX">$F = 27{,}504.36$</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <mi>F</mi> <mo>=</mo> <mn>27</mn> <mo>,</mo> <mn>504.36</mn> </mrow> </math></EquationSource> </InlineEquation>, <InlineEquation ID="IEq5"> <EquationSource Format="TEX">$p < 0.001$</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <mi>p</mi> <mo><</mo> <mn>0.001</mn> </mrow> </math></EquationSource> </InlineEquation>). The low standard deviation (<InlineEquation ID="IEq6"> <EquationSource Format="TEX">$\text {SD} = 5.51$</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <mtext>SD</mtext> <mo>=</mo> <mn>5.51</mn> </mrow> </math></EquationSource> </InlineEquation>) implies a minimal difference between predicted and simulated peak temperatures. Precise regulation of heat transfer behavior is vital to ensure proper tool design and parameter selection during the FSW of maraging steel. The study directly deals with transient heat transfer behavior during FSW, which leads to its wider application in advanced structural alloys.</p>

A transient heat transfer investigation of friction stir joining of maraging steel

期刊论文
发表日期：

2026年1月6日

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K. N. Nouranga,
B. N. Prashanth,
T. Ram Prabhu

摘要

Maraging steel, known for its high tensile strength and fracture toughness, is crucial in high-performance aerospace applications like airplane landing gear, helicopter undercarriages, and rocket engine casings. FSW, a solid-state joining procedure, is frequently utilized for softer materials, including aluminum, magnesium, and zinc. Its efficacy has generated interest in using FSW in steel and titanium alloys. High strength and heat generation make welding maraging steel problematic and affect deformation, residual stresses, and joint stability. This study employs Comsol Multiphysics to conduct a transient heat transfer analysis of FSW in maraging steel, focusing on understanding heat distribution and predicting peak temperature obtained in the workpiece under different rotational speeds and welding speeds. The simulation analyzes the peak temperature obtained during FSW of maraging steel at various tool rotational speeds (TRS: 50–250 rpm) and welding speeds (WS: 10–50 mm/min). The findings indicate that when TRS increases, the peak temperature increases, whereas increasing WS causes the peak temperature to decrease. TRS is recognized as the most significant factor determining thermal input. The numerical model has been evaluated using Response Surface Methodology (RSM), resulting in outstanding statistical agreement ( $R^{2} = 99.99\%$ $R^{2} = 99.99 %$ , adjusted $R^{2} = 99.97\%$ $R^{2} = 99.97 %$ , projected $R^{2} = 99.86\%$ $R^{2} = 99.86 %$ ). Tool rotational speed (TRS) exhibited the greatest impact, as confirmed by ANOVA ( $F = 27{,}504.36$ $F = 27, 504.36$ , $p < 0.001$ $p < 0.001$ ). The low standard deviation ( $\text {SD} = 5.51$ $SD = 5.51$ ) implies a minimal difference between predicted and simulated peak temperatures. Precise regulation of heat transfer behavior is vital to ensure proper tool design and parameter selection during the FSW of maraging steel. The study directly deals with transient heat transfer behavior during FSW, which leads to its wider application in advanced structural alloys.