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<p>High-speed friction stir welding (HS-FSW) addresses the inherent limitations of conventional FSW, such as high axial force and low efficiency. However, the strong coupling of thermal, mechanical, and flow phenomena under high-speed conditions complicates mechanism interpretation and process optimization. This study develops a three-dimensional coupled eulerian–lagrangian (CEL) model for HS-FSW of 6061-T6 aluminum alloy. The model incorporates a dual heat source—frictional and plastic deformation—together with the Johnson–Cook constitutive law and a Zener-Hollomon-based viscosity to capture non-Newtonian flow behavior. Results show that higher rotational speed enhances material flow and stabilizes vortex structures, whereas faster welding speed reduces heat input, producing a narrower nugget zone. Validation by infrared thermography, thermocouples, and cross-sectional observations confirms peak temperature deviations below 4 % and tensile strength up to 91.3 % of the base metal. A novel process parameter index reveals a nonlinear correlation with joint properties, offering guidance for process optimization.</p>

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Multi-field CEL simulation and optimization of high-speed friction stir welding of 6061-T6 aluminum alloy

  • 期刊论文

  • 发表日期：

    2026年7月11日

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  • Taotao Jin,
  • Chuanyue Qi,
  • Weihao Xu,
  • He Ma,
  • Xiuhui Cui

摘要

High-speed friction stir welding (HS-FSW) addresses the inherent limitations of conventional FSW, such as high axial force and low efficiency. However, the strong coupling of thermal, mechanical, and flow phenomena under high-speed conditions complicates mechanism interpretation and process optimization. This study develops a three-dimensional coupled eulerian–lagrangian (CEL) model for HS-FSW of 6061-T6 aluminum alloy. The model incorporates a dual heat source—frictional and plastic deformation—together with the Johnson–Cook constitutive law and a Zener-Hollomon-based viscosity to capture non-Newtonian flow behavior. Results show that higher rotational speed enhances material flow and stabilizes vortex structures, whereas faster welding speed reduces heat input, producing a narrower nugget zone. Validation by infrared thermography, thermocouples, and cross-sectional observations confirms peak temperature deviations below 4 % and tensile strength up to 91.3 % of the base metal. A novel process parameter index reveals a nonlinear correlation with joint properties, offering guidance for process optimization.