Analysis of Temperature and Residual Stress Distribution in Friction Stir Welded Tailored Blank of Dissimilar Aluminium Alloy: Insights from Numerical Simulation and Experimental Observations.
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| Title: | Analysis of Temperature and Residual Stress Distribution in Friction Stir Welded Tailored Blank of Dissimilar Aluminium Alloy: Insights from Numerical Simulation and Experimental Observations. |
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| Authors: | Shrivastava, P.1 (AUTHOR) shrivastavap@nitj.ac.in, Chavhan, S.2 (AUTHOR) |
| Source: | Experimental Techniques. Apr2026, Vol. 50 Issue 2, p271-288. 18p. |
| Subjects: | Friction stir welding, Residual stresses, Finite element method, Thermomechanical properties of metals, Aluminum alloys, Microstructure, Computer simulation, Materials analysis |
| Abstract: | This study investigates the thermomechanical and microstructural evolution in dissimilar thin aluminium alloy sheets, AA6061 and AA5182-H34, joined using Friction Stir Welding (FSW), widely adopted in the automotive and aerospace industries for high-strength, lightweight structural applications. Blanks produced via FSW face challenges in joint strength and residual stress development, primarily influenced by peak temperatures generated through frictional heating during the process. A three-dimensional coupled thermo-mechanical finite element model was developed to simulate the FSW process. Experimental validation was achieved using embedded thermocouples and strain rosettes placed strategically along the weld path. Simulation results confirmed successful solid-state bonding, with thermal cycles remaining below the melting points of both alloys. The peak von Mises stress and equivalent plastic strain (PEEQ) occurred near the tool shoulder and advancing side, indicating zones of strain localization and mechanical vulnerability. Longitudinal residual stresses exhibited a distinct M-shaped asymmetric distribution, with peak tensile values reaching 39.21 MPa on the advancing side, while the retreating side showed comparatively lower tensile stresses (36.66 MPa). Transverse residual stresses were significantly lower (~ 70%) and therefore considered secondary in structural assessment. Furthermore, micro-residual stress analysis was performed in conjunction with electron backscatter diffraction (EBSD) metrics. Kernel Average Misorientation (KAM) maps revealed plastic deformation gradients within the nugget zone and thermo-mechanically affected zone (TMAZ), further validating the simulated and experimentally assessed macro residual stress and PEEQ predictions. Dislocation density estimations, derived from KAM values, indicated elevated densities in the weld nugget, confirming residual lattice strain accumulation consistent with differential thermal contraction. The integration of finite element modelling with macro and microscopic residual stress indicators provides a holistic understanding of weld performance. The results contribute to optimized process parameter design and enhance predictive capabilities for fatigue resistance, dimensional stability, and overall joint reliability in thin-sheet dissimilar FSW applications. [ABSTRACT FROM AUTHOR] |
| Copyright of Experimental Techniques is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
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| Items | – Name: Title Label: Title Group: Ti Data: Analysis of Temperature and Residual Stress Distribution in Friction Stir Welded Tailored Blank of Dissimilar Aluminium Alloy: Insights from Numerical Simulation and Experimental Observations. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Shrivastava%2C+P%2E%22">Shrivastava, P.</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> shrivastavap@nitj.ac.in</i><br /><searchLink fieldCode="AR" term="%22Chavhan%2C+S%2E%22">Chavhan, S.</searchLink><relatesTo>2</relatesTo> (AUTHOR) – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Experimental+Techniques%22">Experimental Techniques</searchLink>. Apr2026, Vol. 50 Issue 2, p271-288. 18p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Friction+stir+welding%22">Friction stir welding</searchLink><br /><searchLink fieldCode="DE" term="%22Residual+stresses%22">Residual stresses</searchLink><br /><searchLink fieldCode="DE" term="%22Finite+element+method%22">Finite element method</searchLink><br /><searchLink fieldCode="DE" term="%22Thermomechanical+properties+of+metals%22">Thermomechanical properties of metals</searchLink><br /><searchLink fieldCode="DE" term="%22Aluminum+alloys%22">Aluminum alloys</searchLink><br /><searchLink fieldCode="DE" term="%22Microstructure%22">Microstructure</searchLink><br /><searchLink fieldCode="DE" term="%22Computer+simulation%22">Computer simulation</searchLink><br /><searchLink fieldCode="DE" term="%22Materials+analysis%22">Materials analysis</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: This study investigates the thermomechanical and microstructural evolution in dissimilar thin aluminium alloy sheets, AA6061 and AA5182-H34, joined using Friction Stir Welding (FSW), widely adopted in the automotive and aerospace industries for high-strength, lightweight structural applications. Blanks produced via FSW face challenges in joint strength and residual stress development, primarily influenced by peak temperatures generated through frictional heating during the process. A three-dimensional coupled thermo-mechanical finite element model was developed to simulate the FSW process. Experimental validation was achieved using embedded thermocouples and strain rosettes placed strategically along the weld path. Simulation results confirmed successful solid-state bonding, with thermal cycles remaining below the melting points of both alloys. The peak von Mises stress and equivalent plastic strain (PEEQ) occurred near the tool shoulder and advancing side, indicating zones of strain localization and mechanical vulnerability. Longitudinal residual stresses exhibited a distinct M-shaped asymmetric distribution, with peak tensile values reaching 39.21 MPa on the advancing side, while the retreating side showed comparatively lower tensile stresses (36.66 MPa). Transverse residual stresses were significantly lower (~ 70%) and therefore considered secondary in structural assessment. Furthermore, micro-residual stress analysis was performed in conjunction with electron backscatter diffraction (EBSD) metrics. Kernel Average Misorientation (KAM) maps revealed plastic deformation gradients within the nugget zone and thermo-mechanically affected zone (TMAZ), further validating the simulated and experimentally assessed macro residual stress and PEEQ predictions. Dislocation density estimations, derived from KAM values, indicated elevated densities in the weld nugget, confirming residual lattice strain accumulation consistent with differential thermal contraction. The integration of finite element modelling with macro and microscopic residual stress indicators provides a holistic understanding of weld performance. The results contribute to optimized process parameter design and enhance predictive capabilities for fatigue resistance, dimensional stability, and overall joint reliability in thin-sheet dissimilar FSW applications. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Experimental Techniques is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.1007/s40799-025-00816-2 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 18 StartPage: 271 Subjects: – SubjectFull: Friction stir welding Type: general – SubjectFull: Residual stresses Type: general – SubjectFull: Finite element method Type: general – SubjectFull: Thermomechanical properties of metals Type: general – SubjectFull: Aluminum alloys Type: general – SubjectFull: Microstructure Type: general – SubjectFull: Computer simulation Type: general – SubjectFull: Materials analysis Type: general Titles: – TitleFull: Analysis of Temperature and Residual Stress Distribution in Friction Stir Welded Tailored Blank of Dissimilar Aluminium Alloy: Insights from Numerical Simulation and Experimental Observations. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Shrivastava, P. – PersonEntity: Name: NameFull: Chavhan, S. IsPartOfRelationships: – BibEntity: Dates: – D: 01 M: 04 Text: Apr2026 Type: published Y: 2026 Identifiers: – Type: issn-print Value: 07328818 Numbering: – Type: volume Value: 50 – Type: issue Value: 2 Titles: – TitleFull: Experimental Techniques Type: main |
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