Scholarlink

<p>Despite its critical importance in governing the weld strength and residual stress of dissimilar aluminum/magnesium welds by friction stir welding, the in-process temperature characteristics remain a subject of ongoing debate. This paper aims to resolve this debate through computational fluid dynamics simulation with the best accuracy to date, enabled by a state-of-the-art shear boundary model that allows fully coupled analysis of interfacial friction, material flow, heat generation and heat transfer. It is revealed that the temperature on the magnesium side is higher than that on the aluminum side, despite nearly identical total heat generation rates on both sides. This asymmetry is attributed to magnesium’s lower thermal conductivity, which impedes heat conduction. It is interesting to note that the circumferential temperature variation is reduced in high-velocity zones near the tool pin due to enhanced convection. The accuracy of the simulation is rigorously validated via comprehensive comparison between the measured welding temperature and the observed joint macrograph, confirming its capability to resolve the long-standing debate in the in-process temperature characteristics. These insights shed new lights on the thermal processes regarding the dissimilar aluminum/magnesium FSW, offering a foundation for optimizing welding process and weld 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

Temperature heterogeneity characteristics in dissimilar friction stir welding between aluminum alloy and magnesium alloy: insights from computational fluid dynamics simulations

  • 期刊论文

  • 发表日期：

    2025年8月6日

查看全文
  • Deshuai Kong,
  • Zhao Zhang,
  • Qingyu Shi,
  • Chuansong Wu,
  • Shujun Chen,
  • Zerui Zhao,
  • Chengle Yang,
  • Junnan Qiao,
  • Gaoqiang Chen

摘要

Despite its critical importance in governing the weld strength and residual stress of dissimilar aluminum/magnesium welds by friction stir welding, the in-process temperature characteristics remain a subject of ongoing debate. This paper aims to resolve this debate through computational fluid dynamics simulation with the best accuracy to date, enabled by a state-of-the-art shear boundary model that allows fully coupled analysis of interfacial friction, material flow, heat generation and heat transfer. It is revealed that the temperature on the magnesium side is higher than that on the aluminum side, despite nearly identical total heat generation rates on both sides. This asymmetry is attributed to magnesium’s lower thermal conductivity, which impedes heat conduction. It is interesting to note that the circumferential temperature variation is reduced in high-velocity zones near the tool pin due to enhanced convection. The accuracy of the simulation is rigorously validated via comprehensive comparison between the measured welding temperature and the observed joint macrograph, confirming its capability to resolve the long-standing debate in the in-process temperature characteristics. These insights shed new lights on the thermal processes regarding the dissimilar aluminum/magnesium FSW, offering a foundation for optimizing welding process and weld performance.