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<p>The effects of friction stir processing (FSP) parameters—specifically, rotational speeds (RS: 1000&#xa0;rpm, 1250&#xa0;rpm, 1500&#xa0;rpm) and traverse speeds (TS: 15&#xa0;mm/min, 30&#xa0;mm/min, 45&#xa0;mm/min)—on the microstructure and temperature distribution of WE43 magnesium alloy have been systematically investigated. The optimal combination of RS 1250&#xa0;rpm and TS 30&#xa0;mm/min produced the finest microstructure with an average grain size of 4.32&#xa0;μm, indicating effective dynamic recrystallization. A predictive mathematical model based on response surface methodology (RSM) was established to quantify the influence of RS and TS on grain size, RS was the dominant factor and the model showed strong fidelity (<i>R</i><sup>2</sup> ≈ 0.98, Adeq precision ≈ 17). Furthermore, temperature distribution during FSP was analyzed using both theoretical calculations and finite element simulations in Abaqus. The results revealed notable temperature gradients between different zones, particularly between the advancing and retreating sides, with RS having a stronger influence on heat generation. These findings contribute to a deeper understanding of microstructural evolution and thermal behavior in WE43 alloy during FSP, offering practical guidance for process optimization. The insights are also relevant to future applications in biomedical implants, where grain refinement and thermal control are essential for improving corrosion resistance and mechanical performance.</p>

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Effect of Friction Stir Processing Parameters on Microstructure and Temperature Distribution of WE43 Mg Alloy

  • 期刊论文

  • 发表日期：

    2025年9月18日

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  • Bo Wu,
  • Luyong Cai,
  • Shuaibin Shang,
  • Farazila Yusof,
  • Hongqun Tang,
  • Zhengbing Xu,
  • Mahmoud. Z. Ibrahim

摘要

The effects of friction stir processing (FSP) parameters—specifically, rotational speeds (RS: 1000 rpm, 1250 rpm, 1500 rpm) and traverse speeds (TS: 15 mm/min, 30 mm/min, 45 mm/min)—on the microstructure and temperature distribution of WE43 magnesium alloy have been systematically investigated. The optimal combination of RS 1250 rpm and TS 30 mm/min produced the finest microstructure with an average grain size of 4.32 μm, indicating effective dynamic recrystallization. A predictive mathematical model based on response surface methodology (RSM) was established to quantify the influence of RS and TS on grain size, RS was the dominant factor and the model showed strong fidelity (R2 ≈ 0.98, Adeq precision ≈ 17). Furthermore, temperature distribution during FSP was analyzed using both theoretical calculations and finite element simulations in Abaqus. The results revealed notable temperature gradients between different zones, particularly between the advancing and retreating sides, with RS having a stronger influence on heat generation. These findings contribute to a deeper understanding of microstructural evolution and thermal behavior in WE43 alloy during FSP, offering practical guidance for process optimization. The insights are also relevant to future applications in biomedical implants, where grain refinement and thermal control are essential for improving corrosion resistance and mechanical performance.