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<p>Defect formation during friction stir welding (FSW) of aluminum and copper was simulated using the finite-element method. The coupled Eulerian–Lagrangian (CEL) model was used to predict defect formation, temperature dynamics, and material flow behavior during FSW. Defect formation was studied by changing the tool rotation speed from 800 to 1000 rpm and the welding rate from 25&#xa0;to 63 mm/min at a&#xa0;constant tool angle of 3° and offset toward the copper. The CEL model predicts the tunnel size with an error of approximately 18% at high rotation speeds (1000 rpm) and 25% at low speeds (800 rpm) compared to the experimental one. Defect-free welded joints of copper and aluminum were obtained at a&#xa0;minimum welding rate of 25 mm/min and a&#xa0;tool speed of 900 rpm. The model also revealed that the welding rate significantly affects the void size and shape, with elliptical voids forming at 63 mm/min and a&#xa0;more rounded voids at 41 mm/min. At low welding rates, the void sizes reduced by approximately 10%.</p>

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Simulation of defect formation during friction stir welding of aluminum and copper

  • 期刊论文

  • 发表日期：

    2025年3月14日

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  • Radmir A. Rzaev,
  • Leonid M. Gurevich,
  • Alfiya G. Valisheva

摘要

Defect formation during friction stir welding (FSW) of aluminum and copper was simulated using the finite-element method. The coupled Eulerian–Lagrangian (CEL) model was used to predict defect formation, temperature dynamics, and material flow behavior during FSW. Defect formation was studied by changing the tool rotation speed from 800 to 1000 rpm and the welding rate from 25 to 63 mm/min at a constant tool angle of 3° and offset toward the copper. The CEL model predicts the tunnel size with an error of approximately 18% at high rotation speeds (1000 rpm) and 25% at low speeds (800 rpm) compared to the experimental one. Defect-free welded joints of copper and aluminum were obtained at a minimum welding rate of 25 mm/min and a tool speed of 900 rpm. The model also revealed that the welding rate significantly affects the void size and shape, with elliptical voids forming at 63 mm/min and a more rounded voids at 41 mm/min. At low welding rates, the void sizes reduced by approximately 10%.