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Indexed by:Journal Papers

Date of Publication:2024-05-10

Journal:International Journal of Advanced Manufacturing Technology

Volume:129

Issue:9-10

Page Number:4201-4215

ISSN No.:0268-3768

Key Words:Friction stir welding; Process parameters; Optimal selection; Temperature analysis; 2219 aluminum alloy; Thick plate

Abstract:Optimal selection of friction stir welding (FSW) process parameters is critical for ensuring an even temperature distribution and high weld quality. This study ascertained the impact of process parameters on temperature distribution in the core area of friction stir welded 2219 aluminum alloy thick plate and determined the optimal combination (the range of rotational
speed was estimated as 457.15–500.00 r/min, the welding speed was found within the range of 68.50–84.75 mm/min) of
these parameters. The FSW process simulation model of 2219 aluminum alloy thick plate was established using DEFORM.
The temperature field simulations of plunging, dwelling, welding, and withdrawal phases of FSW were also realized. Thermocouple temperature measurement experiments were performed to validate the model. The impact of welding process parameters on the core area’s maximum temperature and temperature difference was also investigated. The polynomial fitting
method was used to establish a prediction model based on maximum and minimum temperatures of the FSW core area. The
surface-fitting method was applied to draw the fitting surfaces of maximum and minimum temperatures, which intersected
with the upper and inferior limit planes of reasonable welding temperature of 2219 aluminum alloy material, respectively.
The intersection line was projected onto the plane with welding and rotational speeds as horizontal and vertical coordinates,
respectively, and the optimized combination of welding process parameters was obtained.