Friction stir welding of AA6082 and AA5083 T-joints for naval applications: Finite element modeling and experimental analysis of material flow
Guido Di Bella, Mohamed Chairi, Davide Campanella, Riccardo Puleo, Gianluca Buffa
Abstract. This study investigates the influence of rotational speed on material flow during friction stir welding (FSW) of dissimilar aluminum T-joints made of AA6082 and AA5083 alloys for naval applications. A finite element (FE) model was used to simulate the thermomechanical behavior and visualize the material flow during the welding process. Simulations were carried out at two rotational speeds, 500 rpm and 900 rpm, to evaluate their effects on heat distribution, strain rate and deformation patterns. The numerical results show that higher speeds improve plasticization and material mixing but also increase the risk of defect formation due to excessive heat input. The simulation outcomes are confirmed by the experimental observations made in the previous study, particularly with regards to the formation of heat-affected zones (HAZ) associated with the microhardness variations.
Keywords
Friction Stir Welding, Tensile Strength, Aluminum Alloys
Published online 9/10/2025, 8 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Guido Di Bella, Mohamed Chairi, Davide Campanella, Riccardo Puleo, Gianluca Buffa, Friction stir welding of AA6082 and AA5083 T-joints for naval applications: Finite element modeling and experimental analysis of material flow, Materials Research Proceedings, Vol. 57, pp 327-334, 2025
DOI: https://doi.org/10.21741/9781644903735-38
The article was published as article 38 of the book Italian Manufacturing Association Conference
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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