A comprehensive investigation of thermal management strategies in dissimilar micro-friction stir welding (dissimilar µFSW): Insights from numerical simulation and experimental observations

Abstract

The increased heat dissipation rate from thin sheets and differences in material properties lead to difficulties in controlling the heat input in dissimilar micro-friction stir welding (dissimilar µFSW). As a result, improper material mixing and defect formation significantly increase, which deteriorates weld performance and escalates its rejection rate. This issue of thermal mismanagement is mitigated in the present work by utilizing suitable material positioning and tool offset strategies during the dissimilar µFSW of 0.5 mm thick AA 2024-T3 and AA 6061-T6. To date, post-weld analysis was predominantly utilized to derive the physics for explaining these strategies in dissimilar µFSW. However, for proper utilization of these strategies, it is important to comprehend the underlying process physics by investigating the parameters that evolved during the process, such as temperature distribution, material flow velocity, and material intermixing. The literature currently available lacks a systematic investigation in this direction. For this purpose, a 3-D thermo-mechanical model based on coupled Eulerian-Lagrangian formulation was employed in this study. The numerical results showed that an optimal temperature difference between the advancing and retreating sides facilitates achieving a higher degree of velocity symmetry with a uniform higher magnitude of velocity vectors. Importantly, this degree of velocity symmetry showed a good agreement with experimentally determined weld characteristics, namely macro and microstructures, and mechanical performance. By appropriate thermal management, a joint efficiency of 77.3 % (weld strength = 243.58 MPa) was obtained upon tensile loading, and the weld fractured from the heat-affected zone of the AA 6061-T6 side, exhibiting characteristics of ductile failure.