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<p>This study focuses on performing a dynamic explicit nonlinear finite element simulation to analyze the temperature, residual stress, and strain distribution during the friction stir welding (FSW) process of zirconium (Zr) nanoparticle-reinforced AA2024-T3 (Zr-AA2024-T3) aluminum alloy. The computational modeling of Zr-reinforced FSW (rFSW) process is performed using ABAQUS explicit software. To ensure the development of a reliable and computationally efficient finite element (FE) model, key features such as the arbitrary Lagrangian–Eulerian (ALE) formulation, adaptive meshing, mesh sensitivity analysis, and mass scaling are integrated. The interaction between the tool bottom surface and the plate upper surface is defined using a finite sliding property. The tool–workpiece contact is modeled with a Coulomb friction model that incorporates a temperature-dependent friction coefficient. Additionally, an experimental study is conducted to validate the results obtained numerically. The results demonstrate similar temperature profiles generated across the workpiece, with slightly higher temperatures observed on the advancing side. The mechanical response of the AA2024-T3 aluminum alloy plates is also investigated. A temperature rise of around 20&#xa0;°C relative to conventional FSW of AA2024-T3 plates is observed in rFSW process. Thermal stresses in Zr-reinforced AA2024-T3 joints show a 38% decrease at the start of the traverse phase as compared to FSW process.</p>

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Thermomechanical Analysis and Experimental Investigation of Zr Nanoparticles Reinforced Friction Stir Welding of AA2024-T3 Alloy

  • 期刊论文

  • 发表日期：

    2026年4月28日

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  • Ranamay Saha,
  • Debraj Das,
  • Kapil Manoharan,
  • Barnik Saha Roy,
  • Pankaj Biswas

摘要

This study focuses on performing a dynamic explicit nonlinear finite element simulation to analyze the temperature, residual stress, and strain distribution during the friction stir welding (FSW) process of zirconium (Zr) nanoparticle-reinforced AA2024-T3 (Zr-AA2024-T3) aluminum alloy. The computational modeling of Zr-reinforced FSW (rFSW) process is performed using ABAQUS explicit software. To ensure the development of a reliable and computationally efficient finite element (FE) model, key features such as the arbitrary Lagrangian–Eulerian (ALE) formulation, adaptive meshing, mesh sensitivity analysis, and mass scaling are integrated. The interaction between the tool bottom surface and the plate upper surface is defined using a finite sliding property. The tool–workpiece contact is modeled with a Coulomb friction model that incorporates a temperature-dependent friction coefficient. Additionally, an experimental study is conducted to validate the results obtained numerically. The results demonstrate similar temperature profiles generated across the workpiece, with slightly higher temperatures observed on the advancing side. The mechanical response of the AA2024-T3 aluminum alloy plates is also investigated. A temperature rise of around 20 °C relative to conventional FSW of AA2024-T3 plates is observed in rFSW process. Thermal stresses in Zr-reinforced AA2024-T3 joints show a 38% decrease at the start of the traverse phase as compared to FSW process.