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This research utilizes ABAQUS/Explicit and its coupled Eulerian–Lagrangian (CEL) capability to simulate the friction stir welding (FSW) process using AA7075. Three tool geometries were analyzed to evaluate their effects on temperature distribution and defect formation. Results show that the tapered threaded tool produces a more uniform temperature field and better material flow. In contrast, cylindrical designs led to asymmetrical deformation and void formation. The findings confirm that tool geometry significantly influences weld quality, and proper selection can minimize defects during FSW.

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Investigation of Tool Geometry on Temperature Field and Defect Formation of Friction Stir Welding Process Using AA7075

  • 会议论文

  • 发表日期：

    2026年

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  • Nguyen Phuc Nhat Minh,
  • Pham Quang Trung,
  • Dinh Duy Khoa,
  • Le Dinh An

摘要

This research utilizes ABAQUS/Explicit and its coupled Eulerian–Lagrangian (CEL) capability to simulate the friction stir welding (FSW) process using AA7075. Three tool geometries were analyzed to evaluate their effects on temperature distribution and defect formation. Results show that the tapered threaded tool produces a more uniform temperature field and better material flow. In contrast, cylindrical designs led to asymmetrical deformation and void formation. The findings confirm that tool geometry significantly influences weld quality, and proper selection can minimize defects during FSW.