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

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 dynami...

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Bibliographic Details
Published in:International journal of material forming Vol. 18; no. 3; p. 71
Main Authors: Kong, Deshuai, Zhang, Zhao, Shi, Qingyu, Wu, Chuansong, Chen, Shujun, Zhao, Zerui, Yang, Chengle, Qiao, Junnan, Chen, Gaoqiang
Format: Journal Article
Language:English
Published: Paris Springer Paris 01.09.2025
Springer Nature B.V
Subjects:
Accuracy
Aluminum alloys
Aluminum base alloys
Behavior
CAE) and Design
Computational fluid dynamics
Computational Intelligence
Computer-Aided Engineering (CAD
Conduction heating
Conductive heat transfer
Control
Dissimilar material joining
Dynamical Systems
Engineering
Enthalpy
Experiments
Fluid dynamics
Friction stir welding
Heat generation
Heat transfer
Heterogeneity
Intermetallic compounds
Machines
Magnesium alloys
Magnesium base alloys
Manufacturing
Materials Science
Mechanical Engineering
Morphology
Photomacrographs
Processes
Residual stress
Simulation
Temperature
Thermal conductivity
Vibration
Weld strength
Welded joints
Heat generation
Numerical simulation
Temperature field
Aluminum-magnesium alloys
Friction stir welding
Heat transfer
ISSN:1960-6206, 1960-6214
Online Access:Get full text
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Summary: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.
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ISSN:1960-6206
1960-6214
DOI:10.1007/s12289-025-01935-2