Paper Titles
Preface
Effect of Magnesium and Silicon on Temperature and Mechanical Properties in Refill Friction Stir Spot Welding of Aluminum to Titanium
p.1
Formation Mechanism of Dense and Uniform Structure during Tailor Welding of Aluminum Foam Structure Preform
p.9
Welding Distortion Control in T-Joint Structure of Al-Sheets by Using Pre-Tension
p.17
Microstructural Characterisations of Static Strain Ageing in C-Mn Steel Welds of the Secondary Circuit of Pressurized Water Reactors
p.23
Creep Properties of P92 Pipe Weld after Annealing at 600 and 650°C
p.31
Application of Electron Beam Welding in the Production of TEMPALOY AA1 and T92 Butt Joints of Pipes Assigned for the Energy Industry
p.39
Evolution of Inclusions in Physically Simulated Heat-Affected Zones of a Weld Metal Used with a 500 MPa Offshore Steel
p.47
Effect of Thermal Cycle Profile on Thermal Fatigue Life of Sn-3.0Ag-0.5Cu Solder Joints for Wafer-Level Chip Scale Package
p.55

Formation Mechanism of Dense and Uniform Structure during Tailor Welding of Aluminum Foam Structure Preform

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Abstract:

To address the long cycle, high cost, and low efficiency of traditional Aluminum Foam Sandwich preform preparation, this study employs Friction Stir Welding to fabricate preforms with uniform powder mixing. Integrated experimental-simulation approaches reveal the formation mechanism. Temperature field analysis via infrared thermography and Fluent simulation confirms a peak temperature of 522°C at 2000 r/min rotation speed, generating an 85°C/mm thermal gradient and expanding the >450°C zone to 1.8 times the shoulder diameter. Concurrently, flow field modeling demonstrates intensified vortex flow at 2000 r/min, with tracer particles verifying uniform TiH₂/Al₂O₃ dispersion and onion ring radius expansion under 50 mm/min welding speed. Microstructural characterization identifies optimal joint quality through refined nugget zone grains averaging 1.3 μm and porosity below 2% at parameters of 2000 r/min rotation speed, 50 mm/min welding speed, 3 mm spacing, and 0.1 mm reduction. These results establish a methodology for regulating preform structural uniformity.

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Periodical:

Key Engineering Materials (Volume 1040)

Pages:

9-16

DOI:

https://doi.org/10.4028/p-EKFo3f

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Online since:

January 2026

Authors:

Jia Zheng, Ming Jen Tan*

Keywords:

AFS Preform, Friction Stir Welding, High Density, Microstructure, Uniform Microstructure

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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* - Corresponding Author

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