Temperature and material flow in one-step double-acting friction stir welding process of aluminum alloy: Modeling and experimental
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Apr 15, 2025
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Abstract
Aluminum, known for its lower density compared to steel, is widely used in various applications. Welding is often required to form aluminum into technical structures. However, when fusion welding is used, it can lead to porosity in the weld. This occurs due to the significant difference in hydrogen gas solubility between liquid and solid aluminum, which traps hydrogen gas within the weld metal. Friction Stir Welding (FSW), a solid-state welding technique, has been proven to minimize porosity. However, for thick structures, FSW poses challenges, as welding must be done on both sides, increasing the welding time. To overcome this limitation, FSW has been modified into a one-step double-side FSW process, where two tools simultaneously work on both surfaces of the workpiece. This creates a unique condition with two heat sources and two stirring motion sources. To understand the temperature distribution and material flow in this process, modeling was conducted using Computational Fluid Dynamics (CFD). The upper and lower tools in the one-step double-side FSW process operate under identical conditions: a rotation speed of 1500 rpm, a welding speed of 30 mm/min, and a tilt angle of 0 degrees. The aluminum plate is treated as fluid, while the tools are considered solid in the model. The results of the temperature distribution modeling were validated against published studies, and the material flow was verified through macro- and microstructural observations of the cross-section. The validation showed that the model is accurate, with an error of only 4.07%.
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References
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[34] D. G. Andrade, C. Leitão, N. Dialami, M. Chiumenti, and D. M. Rodrigues, “Modelling torque and temperature in friction stir welding of aluminium alloys,” International Journal of Mechanical Sciences, vol. 182, p. 105725, Sep. 2020, doi: 10.1016/j.ijmecsci.2020.105725.
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[3] M. I. Hilmawan et al., “Effect of tools rotational speed on the mechanical properties of one-step double-acting friction stir welded aluminum alloy AA 6061 hollow panel,” International Journal of Lightweight Materials and Manufacture, vol. 7, no. 3, pp. 467–479, May 2024, doi: 10.1016/j.ijlmm.2024.02.002.
[4] D. W. Rathod, “A Review on challenges and opportunities in wire arc additive manufacturing of aluminium alloys: Specific context of 7xxx series alloys,” Mechanical Engineering for Society and Industry, vol. 5, no. 1, 2025, doi: 10.31603/mesi.12711.
[5] H. Granum, O. R. Myhr, T. Børvik, and O. S. Hopperstad, “Effect of pre-stretching on the mechanical behaviour of three artificially aged 6xxx series aluminium alloys,” Materials Today Communications, vol. 27, p. 102408, Jun. 2021, doi: 10.1016/j.mtcomm.2021.102408.
[6] Y. Wang, G. Zhao, L. Sun, X. Wang, D. Wei, and L. Liu, “Effects of welding angle on microstructure and mechanical properties of longitudinal weld in 6063 aluminum alloy extrusion profiles,” Journal of Materials Research and Technology, vol. 17, pp. 756–773, Mar. 2022, doi: 10.1016/j.jmrt.2022.01.054.
[7] S. Saifudin, N. Muhayat, E. Surojo, Y. H. Manurung, and T. Triyono, “Mitigation of Porosity and Residual Stress on Carbody Aluminum Alloy Vibration Welding: A Systematic Literature Review,” Automotive Experiences, vol. 5, no. 3, pp. 477–493, Nov. 2022, doi: 10.31603/ae.7965.
[8] B. F. Jogi, A. S. Awale, S. R. Nirantar, and H. S. Bhusare, “Metal Inert Gas (MIG) Welding Process Optimization using Teaching-Learning Based Optimization (TLBO) Algorithm,” Materials Today: Proceedings, vol. 5, no. 2, pp. 7086–7095, 2018, doi: 10.1016/j.matpr.2017.11.373.
[9] R. Kumar et al., “A comparative analysis of friction stir and tungsten inert gas dissimilar AA5082-AA7075 butt welds,” Materials Science for Energy Technologies, vol. 5, pp. 74–80, 2022, doi: 10.1016/j.mset.2021.12.002.
[10] T. Fiegl, M. Franke, A. Raza, E. Hryha, and C. Körner, “Effect of AlSi10Mg0.4 long-term reused powder in PBF-LB/M on the mechanical properties,” Materials & Design, vol. 212, p. 110176, Dec. 2021, doi: 10.1016/j.matdes.2021.110176.
[11] A. Hima Bindu, B. S. K. Chaitanya, K. Ajay, and I. Sudhakar, “Investigation on feasibility of dissimilar welding of AA2124 and AA7075 aluminium alloy using tungsten inert gas welding,” Materials Today: Proceedings, vol. 26, pp. 2283–2288, 2020, doi: 10.1016/j.matpr.2020.02.494.
[12] R. D. Ardika, T. Triyono, N. Muhayat, and Triyono, “A review porosity in aluminum welding,” Procedia Structural Integrity, vol. 33, pp. 171–180, 2021, doi: 10.1016/j.prostr.2021.10.021.
[13] Saifudin, N. Muhayat, E. Surojo, M. R. Muslih, and Triyono, “Effect of vibration frequency on mechanical properties and microstructure of metal inert gas welded dissimilar AA5083 and AA6061 aluminum alloy joints,” Results in Engineering, vol. 24, p. 102970, Dec. 2024, doi: 10.1016/j.rineng.2024.102970.
[14] Z. Afriansyah, M. Ashof, and A. Naimah, “Comparison of SMAW and GTAW Welding Properties,” Mechanics Exploration and Material Innovation, vol. 1, no. 2, pp. 48–53, Apr. 2024, doi: 10.21776/ub.memi.2024.001.02.2.
[15] S. Kotari, E. Punna, S. M. Gangadhar Reddy, and S. Venukumar, “Mechanical and micro structural behaviour of flux coated GTAW and FSW joined AA6061 aluminium alloy,” Materials Today: Proceedings, vol. 27, pp. 1660–1667, 2020, doi: 10.1016/j.matpr.2020.03.562.
[16] E. Sharghi and A. Farzadi, “Simulation of strain rate, material flow, and nugget shape during dissimilar friction stir welding of AA6061 aluminum alloy and Al-Mg2Si composite,” Journal of Alloys and Compounds, vol. 748, pp. 953–960, Jun. 2018, doi: 10.1016/j.jallcom.2018.03.145.
[17] P. Kah, R. Rajan, J. Martikainen, and R. Suoranta, “Investigation of weld defects in friction-stir welding and fusion welding of aluminium alloys,” International Journal of Mechanical and Materials Engineering, vol. 10, no. 1, p. 26, Dec. 2015, doi: 10.1186/s40712-015-0053-8.
[18] D. B. Darmadi and M. Talice, “Improving the strength of friction stir welded joint by double side friction welding and varying pin geometry,” Engineering Science and Technology, an International Journal, vol. 24, no. 3, pp. 637–647, Jun. 2021, doi: 10.1016/j.jestch.2020.11.001.
[19] Hendrato, P. Puspitasari, Jamasri, and Triyono, “Fatigue crack growth rate and mechanical properties of one-step double-side friction stir welded AA6061-T6,” Results in Engineering, vol. 21, p. 101958, Mar. 2024, doi: 10.1016/j.rineng.2024.101958.
[20] S. Sivabalan, R. Sridhar, A. Parthiban, and G. Sathiskumar, “Experimental investigations of mechanical behavior of friction stir welding on aluminium alloy 6063,” Materials Today: Proceedings, vol. 37, pp. 1678–1684, 2021, doi: 10.1016/j.matpr.2020.07.236.
[21] H. Jia, K. Wu, and Y. Sun, “Numerical and experimental study on the thermal process, material flow and welding defects during high-speed friction stir welding,” Materials Today Communications, vol. 31, p. 103526, Jun. 2022, doi: 10.1016/j.mtcomm.2022.103526.
[22] F. R. Putra, A. S. Pramana, B. S. Pamungkas, R. Maulyansyah, W. Suprapto, and A. A. J. Al-Hchaimi, “Effect of Stirring Time in Induction Furnace on Density, Porosity, Efficiency, Fluidity, and Geometry of Al-Mg-Si Castings,” Mechanics Exploration and Material Innovation, vol. 1, no. 3, pp. 88–93, Jul. 2024, doi: 10.21776/ub.memi.2024.001.03.3.
[23] D. Priyasudana et al., “Double side friction stir welding effect on mechanical properties and corrosion rate of aluminum alloy AA6061,” Heliyon, vol. 9, no. 2, p. e13366, Feb. 2023, doi: 10.1016/j.heliyon.2023.e13366.
[24] D. Ambrosio, Y. Morisada, K. Ushioda, and H. Fujii, “Material flow in friction stir welding: A review,” Journal of Materials Processing Technology, vol. 320, p. 118116, Nov. 2023, doi: 10.1016/j.jmatprotec.2023.118116.
[25] Y. Sharma, A. Mehta, H. Vasudev, N. Jeyaprakash, G. Prashar, and C. Prakash, “Analysis of friction stir welds using numerical modelling approach: a comprehensive review,” International Journal on Interactive Design and Manufacturing (IJIDeM), vol. 18, no. 8, pp. 5329–5342, Oct. 2024, doi: 10.1007/s12008-023-01324-6.
[26] R. P. Youlia, W. Li, Y. Su, Y. Tang, and D. Utami, “Effectiveness and efficiency of tool alignment and simultaneity factors on double-sided friction stir welding for joining heat-treatable aluminum alloys: a review,” Welding in the World, vol. 69, no. 2, pp. 407–430, Feb. 2025, doi: 10.1007/s40194-024-01867-6.
[27] R. Mohan, J. U.B., and M. R., “CFD modelling of ultra-high rotational speed micro friction stir welding,” Journal of Manufacturing Processes, vol. 64, pp. 1377–1386, Apr. 2021, doi: 10.1016/j.jmapro.2021.02.060.
[28] Mohd Anees Siddiqui, S. A. H. Jafri, and Shahnawaz Alam, “Validation of Maximum Temperature during Friction Stir Welding of Butt Joint of Aluminium Alloy by using HyperWorks,” International Journal of Engineering Research and, vol. V4, no. 04, Apr. 2015, doi: 10.17577/IJERTV4IS041182.
[29] A. K. Kadian and P. Biswas, “A Comparative Study of Material Flow Behavior in Friction Stir Welding Using Laminar and Turbulent Models,” Journal of Materials Engineering and Performance, vol. 24, no. 10, pp. 4119–4127, Oct. 2015, doi: 10.1007/s11665-015-1520-3.
[30] O. P. Abolusoro, E. T. Akinlabi, and S. V. Kailas, “Tool rotational speed impact on temperature variations, mechanical properties and microstructure of friction stir welding of dissimilar high-strength aluminium alloys,” Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol. 42, no. 4, p. 176, Apr. 2020, doi: 10.1007/s40430-020-2259-9.
[31] S. Chen et al., “Study on in-situ material flow behaviour during friction stir welding via a novel material tracing technology,” Journal of Materials Processing Technology, vol. 297, p. 117205, Nov. 2021, doi: 10.1016/j.jmatprotec.2021.117205.
[32] Y. Huang et al., “Material-flow behavior during friction-stir welding of 6082-T6 aluminum alloy,” The International Journal of Advanced Manufacturing Technology, vol. 87, no. 1–4, pp. 1115–1123, Oct. 2016, doi: 10.1007/s00170-016-8603-7.
[33] D. Zhang, P. Jiang, Q. Tang, Y. Lv, Q. Ran, and X. Chen, “Simulation of Material Flow Behavior during Friction Stir Welding of 7075 Aluminum Alloy,” Journal of Materials Engineering and Performance, Jun. 2024, doi: 10.1007/s11665-024-09715-w.
[34] D. G. Andrade, C. Leitão, N. Dialami, M. Chiumenti, and D. M. Rodrigues, “Modelling torque and temperature in friction stir welding of aluminium alloys,” International Journal of Mechanical Sciences, vol. 182, p. 105725, Sep. 2020, doi: 10.1016/j.ijmecsci.2020.105725.
[35] R. Jain, S. K. Pal, and S. B. Singh, “A study on the variation of forces and temperature in a friction stir welding process: A finite element approach,” Journal of Manufacturing Processes, vol. 23, pp. 278–286, Aug. 2016, doi: 10.1016/j.jmapro.2016.04.008.
[36] A. Silva-Magalhães, J. De Backer, J. Martin, and G. Bolmsjö, “In-situ temperature measurement in friction stir welding of thick section aluminium alloys,” Journal of Manufacturing Processes, vol. 39, pp. 12–17, Mar. 2019, doi: 10.1016/j.jmapro.2019.02.001.
[37] M. H. Miah, D. S. Chand, and G. S. Malhi, “Friction stir welding on temperature field for aluminum alloy based on combined HSM,” Materials Today: Proceedings, vol. 56, pp. 675–680, 2022, doi: 10.1016/j.matpr.2022.01.101.
[38] V. Pandian and S. Kannan, “Numerical prediction and experimental investigation of aerospace-grade dissimilar aluminium alloy by friction stir welding,” Journal of Manufacturing Processes, vol. 54, pp. 99–108, Jun. 2020, doi: 10.1016/j.jmapro.2020.03.001.
[39] Z. Sun and C. S. Wu, “Influence of tool thread pitch on material flow and thermal process in friction stir welding,” Journal of Materials Processing Technology, vol. 275, p. 116281, Jan. 2020, doi: 10.1016/j.jmatprotec.2019.116281.