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Development of a Finite Element Model for Thermal Analysis of FSW Butt Welding of AA2124/SiC/25p-T4 Aluminium Metal Matrix Composite

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Abstract:

This study investigates the thermal distribution in high-stregth AA2124/SiC/25p-T4 metal matrix composite during friction stir welding (FSW), a process that allows welding of these materials that are difficult or impossible to be welded by conventional welding methods. To understand the process mechanisms, a transient, 3D thermo-mechanical finite element mode (FEM) was developed. The model calculates temperature distribution during FSW welding by considering boundary conditions such as rotational speed, welding speed, tool pressure, tool diameter and material properties, accounting for conduction and convection heat transfer. The numerical results are validated against experimental data, demonstrating the model’s effectiveness in predicting the impact of varying parameters and aiding in the selection of optimal welding conditions before costly physical trials.

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Periodical:

Materials Science Forum (Volume 1163)

Pages:

79-90

DOI:

https://doi.org/10.4028/p-9ZDu8N

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Online since:

October 2025

Authors:

Marius Pop-Calimanu*, Ion Aurel Perianu

Keywords:

Finite Element Method, Friction Stir Welding, Metal Matrix Composite

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© 2025 Trans Tech Publications Ltd. All Rights Reserved

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