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<p>Friction stir welding (FSW) is a solid-state welding method where mechanical and thermal changes are still not fully understood as a result of the complex nature of the phenomena involved. Theoretical simulation of the welding procedure performs a crucial function in predicting system behavior and optimization of the parameters and their levels. In this paper, an improved finite element model (FEM) was developed that considers time-dependent material properties and coupled thermal and mechanical analyses to investigate temperature and stress distribution during the process for dissimilar sheet metals of 304L stainless steel and Ti-6Al-4V alloy. The model incorporates various aspects such as the wear-resistant rotating tool, tool-workpiece geometry, temperature dependent material properties, travel, and tool rotation. The heat input in advancing and retreating side, frictional stress that leads the change in residual stress also investigated in detail. The model accurately simulates the processes at the tool-workpiece interface, where the developed model is validated with consistent accuracy compared to experimental results for the residual stress and temperature distribution parameters. The novelty of this work lies in addressing the limited literature on FSW of high-strength steel–titanium dissimilar pairs and in providing a validated thermo-mechanical FEM framework capable of capturing both temperature and residual stress under various rotational speed. A comparison of FSW trials revealed that the peak temperatures at 300&#xa0;rpm and 350&#xa0;rpm reach 977.35&#xa0;°C and 1203.6&#xa0;°C respectively. At 300&#xa0;rpm 22.2&#xa0;MPa stress difference observed from surface to depth of 1.59&#xa0;mm (midpoint). However, for non-optimal FSW conditions sharp decrease and increase observed in the peak temperature and residual stress. In addition, the advancing side exhibited higher peak heat flux (~ 7&#xa0;W/mm²) compared to the retreating side (~ 4&#xa0;W/mm²), reflecting inherent process asymmetry. These findings provide the predictive capability of the proposed FEM framework for weld quality assessment.</p>

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Effect of tool rotation speed on thermo-mechanical behavior in dissimilar FSW of 304L stainless steel and Ti–6Al–4V: a FEM-based approach

  • 期刊论文

  • 发表日期：

    2026年2月2日

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  • Gulustan Tugce Alvali,
  • Yasin Sarikavak

摘要

Friction stir welding (FSW) is a solid-state welding method where mechanical and thermal changes are still not fully understood as a result of the complex nature of the phenomena involved. Theoretical simulation of the welding procedure performs a crucial function in predicting system behavior and optimization of the parameters and their levels. In this paper, an improved finite element model (FEM) was developed that considers time-dependent material properties and coupled thermal and mechanical analyses to investigate temperature and stress distribution during the process for dissimilar sheet metals of 304L stainless steel and Ti-6Al-4V alloy. The model incorporates various aspects such as the wear-resistant rotating tool, tool-workpiece geometry, temperature dependent material properties, travel, and tool rotation. The heat input in advancing and retreating side, frictional stress that leads the change in residual stress also investigated in detail. The model accurately simulates the processes at the tool-workpiece interface, where the developed model is validated with consistent accuracy compared to experimental results for the residual stress and temperature distribution parameters. The novelty of this work lies in addressing the limited literature on FSW of high-strength steel–titanium dissimilar pairs and in providing a validated thermo-mechanical FEM framework capable of capturing both temperature and residual stress under various rotational speed. A comparison of FSW trials revealed that the peak temperatures at 300 rpm and 350 rpm reach 977.35 °C and 1203.6 °C respectively. At 300 rpm 22.2 MPa stress difference observed from surface to depth of 1.59 mm (midpoint). However, for non-optimal FSW conditions sharp decrease and increase observed in the peak temperature and residual stress. In addition, the advancing side exhibited higher peak heat flux (~ 7 W/mm²) compared to the retreating side (~ 4 W/mm²), reflecting inherent process asymmetry. These findings provide the predictive capability of the proposed FEM framework for weld quality assessment.