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<p>The selection of appropriate dwell time and welding speed to achieve defect-free, structurally sound joints via friction stir welding (FSW) is time-consuming. In this study, a multi-scale model for FSW is developed based on dynamic mesh and the multi-order-parameter phase-field method, which accounts for both the dwell and welding stages. The developed multi-scale model bridges the gap from process to microstructure, which allows for the prediction of the temperature field, plastic flow, strain, nucleation process, and grain size. The calculated thermal cycles and grain size for various dwell times and welding speeds agreed well with the corresponding experimental results. It was found that the thermal cycles and strain history are the dominant factors governing the nucleation rate in the nugget zone. Higher nucleation rates could be achieved by increasing the peak temperature, and by using longer dwell times and slower welding speeds.</p>

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Multi-Scale Modeling of Dynamic Recrystallization During Friction Stir Welding of Aluminum Alloy Considering Dwell and Welding Stages

  • 期刊论文

  • 发表日期：

    2026年5月11日

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  • Haihua Wei,
  • Wenmin Ou,
  • Guolin Guo,
  • Yuqiang Han,
  • Lili Fan

摘要

The selection of appropriate dwell time and welding speed to achieve defect-free, structurally sound joints via friction stir welding (FSW) is time-consuming. In this study, a multi-scale model for FSW is developed based on dynamic mesh and the multi-order-parameter phase-field method, which accounts for both the dwell and welding stages. The developed multi-scale model bridges the gap from process to microstructure, which allows for the prediction of the temperature field, plastic flow, strain, nucleation process, and grain size. The calculated thermal cycles and grain size for various dwell times and welding speeds agreed well with the corresponding experimental results. It was found that the thermal cycles and strain history are the dominant factors governing the nucleation rate in the nugget zone. Higher nucleation rates could be achieved by increasing the peak temperature, and by using longer dwell times and slower welding speeds.