Numerical Simulation Study on Friction Stir Processing Technology Using DEFORM-3D

Magnesium alloys, celebrated for their low density and outstanding specific strength, are widely employed in lightweight engineering applications. However, their limited ductility imposes constraints on certain uses. Friction stir processing (FSP), an essential technique for enhancing material properties and achieving grain refinement, necessitates precise control over key variables such as temperature distribution during processing. This study adopts a combined numerical simulation and experimental methodology to investigate the evolution of the temperature field in AZ31B magnesium alloy FSP processes. The findings indicate that the peak temperature of the workpieces exhibits a positive correlation with the ratio of stirring head rotational speed to linear velocity. Higher ratios yield increased thermal input. Augmenting either the shoulder pressing depth or shoulder dimensions markedly enhances thermal input by enlarging the contact area. These results provide crucial theoretical foundations and empirical validation for optimizing FSP process parameters and improving the mechanical properties of magnesium alloys.