Numerical Simulation and Metal Fluidity Analysis of Refill Friction Stir Spot Welding Based on 6061 Aluminum Alloy
Simulation analysis is a key technical means for studying the internal metal flow patterns in refill friction stir spot welding zones. This study used DeformV11.0 software to establish an accurate and reliable numerical simulation model for 6061-T6 aluminum alloy refill friction stir spot welding. T...
Saved in:
| Main Authors: | , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-06-01
|
| Series: | Crystals |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2073-4352/15/6/555 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1849471982672805888 |
|---|---|
| author | Di Jiang Igor Kolupaev Hongfeng Wang Xiaole Ge |
| author_facet | Di Jiang Igor Kolupaev Hongfeng Wang Xiaole Ge |
| author_sort | Di Jiang |
| collection | DOAJ |
| description | Simulation analysis is a key technical means for studying the internal metal flow patterns in refill friction stir spot welding zones. This study used DeformV11.0 software to establish an accurate and reliable numerical simulation model for 6061-T6 aluminum alloy refill friction stir spot welding. The microstructure of different stages during actual welding was obtained using the stop method, and combined with the simulation results, shows that the temperature in the spot welding zone is highest during the dwell stage, with a high degree of match between the temperature distribution and actual measurements. This stage is also crucial for affecting the refill process. The results indicate that the metal flow rate in the center of the spot welding zone is slow and the pressure is low, while the flow rate on both sides is fast, and the temperature and pressure are high. In addition, the metal in the weld zone flows plastically in a shear friction and in situ spinning manner, and the weld zone achieves connection in a form similar to “complete friction plug riveting”. A “spiral suction–refill injection layer stacking” model was established to describe the forming mechanism of refill friction stir spot welding. |
| format | Article |
| id | doaj-art-79379948811a4c2c8fd258c3ed760e88 |
| institution | Kabale University |
| issn | 2073-4352 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Crystals |
| spelling | doaj-art-79379948811a4c2c8fd258c3ed760e882025-08-20T03:24:39ZengMDPI AGCrystals2073-43522025-06-0115655510.3390/cryst15060555Numerical Simulation and Metal Fluidity Analysis of Refill Friction Stir Spot Welding Based on 6061 Aluminum AlloyDi Jiang0Igor Kolupaev1Hongfeng Wang2Xiaole Ge3College of Mechanical and Electrical Engineering, Huangshan University, Huangshan 245061, ChinaDepartment of Materials Science, Kharkiv Polytechnic Institute, National Technical University, 61002 Kharkiv, UkraineCollege of Mechanical and Electrical Engineering, Huangshan University, Huangshan 245061, ChinaCollege of Mechanical and Electrical Engineering, Huangshan University, Huangshan 245061, ChinaSimulation analysis is a key technical means for studying the internal metal flow patterns in refill friction stir spot welding zones. This study used DeformV11.0 software to establish an accurate and reliable numerical simulation model for 6061-T6 aluminum alloy refill friction stir spot welding. The microstructure of different stages during actual welding was obtained using the stop method, and combined with the simulation results, shows that the temperature in the spot welding zone is highest during the dwell stage, with a high degree of match between the temperature distribution and actual measurements. This stage is also crucial for affecting the refill process. The results indicate that the metal flow rate in the center of the spot welding zone is slow and the pressure is low, while the flow rate on both sides is fast, and the temperature and pressure are high. In addition, the metal in the weld zone flows plastically in a shear friction and in situ spinning manner, and the weld zone achieves connection in a form similar to “complete friction plug riveting”. A “spiral suction–refill injection layer stacking” model was established to describe the forming mechanism of refill friction stir spot welding.https://www.mdpi.com/2073-4352/15/6/555refill friction stir spot weldingnumerical simulation modelmicrostructureplastic flowformation mechanism |
| spellingShingle | Di Jiang Igor Kolupaev Hongfeng Wang Xiaole Ge Numerical Simulation and Metal Fluidity Analysis of Refill Friction Stir Spot Welding Based on 6061 Aluminum Alloy Crystals refill friction stir spot welding numerical simulation model microstructure plastic flow formation mechanism |
| title | Numerical Simulation and Metal Fluidity Analysis of Refill Friction Stir Spot Welding Based on 6061 Aluminum Alloy |
| title_full | Numerical Simulation and Metal Fluidity Analysis of Refill Friction Stir Spot Welding Based on 6061 Aluminum Alloy |
| title_fullStr | Numerical Simulation and Metal Fluidity Analysis of Refill Friction Stir Spot Welding Based on 6061 Aluminum Alloy |
| title_full_unstemmed | Numerical Simulation and Metal Fluidity Analysis of Refill Friction Stir Spot Welding Based on 6061 Aluminum Alloy |
| title_short | Numerical Simulation and Metal Fluidity Analysis of Refill Friction Stir Spot Welding Based on 6061 Aluminum Alloy |
| title_sort | numerical simulation and metal fluidity analysis of refill friction stir spot welding based on 6061 aluminum alloy |
| topic | refill friction stir spot welding numerical simulation model microstructure plastic flow formation mechanism |
| url | https://www.mdpi.com/2073-4352/15/6/555 |
| work_keys_str_mv | AT dijiang numericalsimulationandmetalfluidityanalysisofrefillfrictionstirspotweldingbasedon6061aluminumalloy AT igorkolupaev numericalsimulationandmetalfluidityanalysisofrefillfrictionstirspotweldingbasedon6061aluminumalloy AT hongfengwang numericalsimulationandmetalfluidityanalysisofrefillfrictionstirspotweldingbasedon6061aluminumalloy AT xiaolege numericalsimulationandmetalfluidityanalysisofrefillfrictionstirspotweldingbasedon6061aluminumalloy |