Abstract

The effects of tool pin thread on the interfacial heat generation, temperature field, material flow and mixing in friction stir welding of Al/Mg alloys was considered to develop a dissimilar FSW model. The physical parameters of materials in the mixing zone were obtained by weighted summation, and the volume fractions of two phases in each control volume were taken as weights. It is found that the role of pin thread is mainly reflected in increasing the mixing extent of the material in the shear layer, which makes the Al/Mg interface more tortuous. The model is experimentally validated by comparing the measured and calculated temperature at the tool/workpiece interface, the TMAZ boundary and the mixed zone width at different horizontal cross-sections.

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