Scholarlink

<p>This study develops an integrated multiphysics computational and experimental framework to evaluate the effect of tool pin geometries in friction stir welding (FSW) of similar AA6061-T6 aluminum alloys. The FSW tool pin plays a critical role in achieving a sound weld joint, as it is primarily responsible for stirring the material under high temperature and pressure conditions during the welding process. Five pin profiles, square (SQ), threaded cylindrical (TH), tapered cylindrical (TC), tapered threaded cylindrical (TCT), and tri-flat (TF), were investigated. Computational modeling revealed that the TCT pin achieved a peak temperature of 476&#xa0;°C with the highest flow velocity and lowest viscosity, indicating efficient stirring and plastic flow. In contrast, the TH pin exhibited the highest peak temperature (506&#xa0;°C) but slightly lower flow velocity. The TF and SQ pins showed disrupted flows with higher viscosity, suggesting poor material mixing. Macrostructural analysis confirmed defect-free stir zones for TCT, minor microvoids for TH, and visible voids for TF and SQ pins. The TCT pin achieved the highest stir zone hardness (85 HV<sub>0.2</sub>) and ultimate tensile strength (160&#xa0;MPa, 8% elongation). The TH pin showed slightly lower strength (150&#xa0;MPa) but better ductility (12%). TF exhibited the lowest strength (110&#xa0;MPa) and elongation (&lt;10%) due to poor stirring and defects. Overall, threaded and tapered pins enhanced material flow and weld quality, with TCT demonstrating superior thermal, mechanical, and microstructural performance.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Development of a Multiphysics Computational Modeling and Experimental Framework for Friction Stir Welding of Similar Aluminum Alloys Using Different Pin Profiles

  • 期刊论文

  • 发表日期：

    2025年9月18日

查看全文
  • Rahul Kesharwani,
  • Rajnish Mishra,
  • Kishor Kumar Jha,
  • Murshid Imam,
  • Chiranjit Sarkar

摘要

This study develops an integrated multiphysics computational and experimental framework to evaluate the effect of tool pin geometries in friction stir welding (FSW) of similar AA6061-T6 aluminum alloys. The FSW tool pin plays a critical role in achieving a sound weld joint, as it is primarily responsible for stirring the material under high temperature and pressure conditions during the welding process. Five pin profiles, square (SQ), threaded cylindrical (TH), tapered cylindrical (TC), tapered threaded cylindrical (TCT), and tri-flat (TF), were investigated. Computational modeling revealed that the TCT pin achieved a peak temperature of 476 °C with the highest flow velocity and lowest viscosity, indicating efficient stirring and plastic flow. In contrast, the TH pin exhibited the highest peak temperature (506 °C) but slightly lower flow velocity. The TF and SQ pins showed disrupted flows with higher viscosity, suggesting poor material mixing. Macrostructural analysis confirmed defect-free stir zones for TCT, minor microvoids for TH, and visible voids for TF and SQ pins. The TCT pin achieved the highest stir zone hardness (85 HV0.2) and ultimate tensile strength (160 MPa, 8% elongation). The TH pin showed slightly lower strength (150 MPa) but better ductility (12%). TF exhibited the lowest strength (110 MPa) and elongation (<10%) due to poor stirring and defects. Overall, threaded and tapered pins enhanced material flow and weld quality, with TCT demonstrating superior thermal, mechanical, and microstructural performance.