Automatic Welding, 2025, №04

2025 №04 (03)

2025 №04 (05)

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"Avtomatychne Zvaryuvannya" (Automatic Welding), #4, 2024, pp. 25-32

Mathematical modeling of thermal processes in friction stir welding of light alloys based on magnesium

O.O. Makhnenko, O.S. Kostenevych, O.V. Makhnenko

E.O. Paton Electric Welding Institute of the NAS of Ukraine 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: makhnenko@paton.kiev.ua

Mathematical modeling of thermal processes in welding is one of the effective methods for predicting the quality of a welded joint depending on technological parameters. However, to develop an adequate mathematical model, it is necessary to take into account a number of factors that can significantly affect the accuracy of the results of the computational analysis. Using the example of the problem of mathematical modeling of temperature distributions in friction stir welding (FSW) of a butt joint of plates of magnesium alloy MA2-1 (AZ31) of different thicknesses (2 mm and 8 mm), a computational study of the distribution of maximum temperatures and thermal cycles in points at different distances from the welded joint axis was carried out. It was found that the results of mathematical modeling of heat conductivity processes during welding heating in FSW are influenced by several aspects, among which one of the significant ones is heat dissipation to the working tool and the restraint devices. Also, to ensure the accuracy of calculation of temperature distributions during FSW, it is important to choose the optimal dimensions of the butt joint model in order to avoid the effect of heat accumulation in a model of a limited size, and to take into account the dependence of the friction coefficient on the temperature of the material, since its value determines the power of heat dissipation in FSW. Based on the results obtained, recommendations are formulated for conducting mathematical modeling of thermal processes in FSW of light alloys. 12 Ref., 4 Tabl., 11 Fig.
Keywords: friction stir welding, temperature distributions, thermal cycles, heat dissipation, work tool, backing plate, mathematical modeling, finite element analysis


Received: 08.04.2025
Received in revised form: 30.06.2025
Accepted: 31.07.2025

References

1. ISO/TS 18166:2016. Numerical welding simulation – Execution and documentation.
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