Numerical Analysis of Micro Stir Friction Welding of 1060-H24 Pure Aluminum Without Shoulder-less Stirring Tool
ZHANG Changqing1,2, MA Dongdong2, GU Huaizhuang2, WANG Dong2, LIU Enrong2, ZHANG Pengsheng3,*
1 State Key Laboratory of Advanced Processing and Recycling of Non-ferrous Metal, Lanzhou University of Technology, Lanzhou 730050, China 2 School of Materials Science and Engineering, Lanzhou University of Technology, Lanzhou 730050, China 3 Northwest Nonferrous Metals Research Institute, Xi’an 710016, China
Abstract: A sequential thermodynamic coupling numerical model was established using ABAQUS finite element software to comparatively analyze the temperature field, stress and joint residual deformation distribution of the miniature friction stir welding process under two stirring tools, shoulder and shoulderless, and the boundary conditions of the heat source model were calibrated using experimental thermocouple temperature measurement. The results show that:the welded joints under the two stirring tools experience different temperatures of the welding thermal cycle, the measured peak temperature of the shoulder tool welded joints is about 362 ℃, while the peak temperature of the welded joints of shoulderless tool is only 143 ℃; the residual stress on the surface of the welded parts is symmetrically distributed in the center of the weld seam, and the shoulder tool residual stress is distributed in the platform of the shoulder region, and the maximum residual stress is 116 MPa. The residual stress on the shoulderless tool is distributed in a spike centered on the stirring needle, with a maximum residual stress of 34 MPa. The residual stress reflects the post-weld deformation, with the thin plate welded by the shoulder tool bulging upwards in the direction of the weld, with a maximum deflection of 2.817 mm. The thin plate welded by the shoulderless tool has no visible deformation, and the maximum deflection is only 0.008 1 mm. Therefore, the low heat input of the shoulderless miniature friction stir welding can effectively reduce the residual deformation of the thin-walled weldment, and improve the dimensional accuracy and assembly quality of the weldment.
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2025, Vol. 39 
