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<p>Due to its solid-state nature, friction stir welding (FSW) revolutionizes the joining of incompatible aluminum and steel in automotive applications, minimizing flaws and the formation of intermetallic compounds (IMCs). Through the calculation of peak temperature and the possible identification of IMCs at the interface, numerical simulations improve the understanding of processes. This research introduces a transient-thermal 3D moving heat source model to simulate the welding phase of FSW lap joining for dissimilar 6061-T6 aluminum and 304 stainless steel. The friction coefficient (0.3 to 0.5), shoulder (16 to 24&#xa0;mm)-to-pin diameter (4.4 to 6.6&#xa0;mm), and tool rotating speeds (600 to 1800&#xa0;rpm) are among the variables being investigated. The results showed a sensitivity to friction coefficients, with a value of 0.4 optimized for peak temperature prediction, compared to the experiments, which had a relative error of less than 10%. In addition, a study has found a direct relationship; heat input increased as the shoulder and pin diameter increased, attributable to the frictional contact area increased. Also, the power intensity decreased as the shoulder and pin diameter increased, resulting in higher heat input and peak temperature during welding. Heat input and peak temperature are directly associated with increased tool rotating speed, with an average 28% increase in peak temperature for every 300&#xa0;rpm increment. These results help industry and academia by guiding the optimization of FSW settings for connecting dissimilar metals.</p>

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Thermal Simulation: Heat Input Impact on Joint Temperatures in Aluminum-Steel Friction Stir Lap Joints

  • 期刊论文

  • 发表日期：

    2025年2月19日

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  • Abhilash,
  • Peerawatt Nunthavarawong,
  • Wallop Ratanathavorn,
  • Pruet Kowitwarangkul,
  • Pandiyarajan Narayanasamy,
  • Kuniaki Dohda

摘要

Due to its solid-state nature, friction stir welding (FSW) revolutionizes the joining of incompatible aluminum and steel in automotive applications, minimizing flaws and the formation of intermetallic compounds (IMCs). Through the calculation of peak temperature and the possible identification of IMCs at the interface, numerical simulations improve the understanding of processes. This research introduces a transient-thermal 3D moving heat source model to simulate the welding phase of FSW lap joining for dissimilar 6061-T6 aluminum and 304 stainless steel. The friction coefficient (0.3 to 0.5), shoulder (16 to 24 mm)-to-pin diameter (4.4 to 6.6 mm), and tool rotating speeds (600 to 1800 rpm) are among the variables being investigated. The results showed a sensitivity to friction coefficients, with a value of 0.4 optimized for peak temperature prediction, compared to the experiments, which had a relative error of less than 10%. In addition, a study has found a direct relationship; heat input increased as the shoulder and pin diameter increased, attributable to the frictional contact area increased. Also, the power intensity decreased as the shoulder and pin diameter increased, resulting in higher heat input and peak temperature during welding. Heat input and peak temperature are directly associated with increased tool rotating speed, with an average 28% increase in peak temperature for every 300 rpm increment. These results help industry and academia by guiding the optimization of FSW settings for connecting dissimilar metals.