Modeling of tensile properties and failure of friction stir welded dissimilar aluminum alloys coupled with process-induced defects
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Author list: Prodkornburee T., Uthaisangsuk V.
Publisher: Springer
Publication year: 2025
Journal: International Journal of Advanced Manufacturing Technology (0268-3768)
Volume number: 136
Issue number: 7
Start page: 3263
End page: 3284
Number of pages: 22
ISSN: 0268-3768
eISSN: 1433-3015
Languages: English-Great Britain (EN-GB)
Abstract
Describing the friction stir welding (FSW) process-related joint performances of dissimilar metals through numerical modeling remains a significant challenge. In this work, FE simulations of FSW for different aluminum grades were performed using the coupled Eulerian–Lagrangian (CEL) approach. The proposed modeling framework provides a convenient tool for predicting the tensile behavior of FSW workpieces, considering the effects of welding parameters, material properties, and process-induced defects. The results of the welding simulations were initially verified by experimentally welded samples, whereby local temperature distributions, sizes of weld zones, microstructures, and hardness profiles were investigated. Afterward, FE simulations of tensile tests for welded samples were performed. Mini-tensile samples were prepared from different weld regions, and gathered stress–strain curves were individually used as their elastic–plastic behaviors in the simulations. For the thermo-mechanically affected zone (TMAZ), nanoindentation was specifically conducted, and its flow stress curve was determined using the Nix-Gao model. Moreover, the Gurson–Tvergaard–Needleman (GTN) ductile damage model was applied, in which defects and voids in welded samples predicted by the CEL-based FSW simulations were characterized and given as initial void fractions of each zone. The calculated void volume fractions agreed with measured data using the CT scan. Overall stress–strain responses predicted by the approach coupled with process-induced defects well described the experimental curves with error less than 3.7%. Finally, the joint performances of FSW specimens could be evaluated precisely concerning various welding parameters. The heat-affected zone (HAZ) of the AA6061 side proved to be the most critical due to its lower hardness, flow stress, and higher defects. This was caused by incomplete material mixing during FSW on the advancing side, accurately modeled by the CEL. Welding speeds between 85–95 mm/min and rotational speeds between 700 and 1100 rpm yielded consistent tensile properties. Deviating from this range weakened the welded workpieces significantly up to strength and elongation reductions of 22% and 43%, respectively. © The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2025.
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