Journal of Advanced Joining Processes最新文献

Linear friction welding of T-Joints in low carbon steel: Effect of welding parameters on joint quality 低碳钢 T 型接头的线性摩擦焊：焊接参数对接头质量的影响

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100267

Huilin Miao , Takayuki Yamashita , Kohsaku Ushioda , Seiichiro Tsutsumi , Yoshiaki Morisada , Hidetoshi Fujii

Linear friction welding (LFW) is a well-established solid-state joining technique. However, its application in T-joint configurations remains unexplored. This study investigated the effects of welding parameters, such as oscillation direction, upset, and applied pressure after oscillation, on linear friction welded (LFWed) T-joints using low-carbon steel SM490A. The flash ejection behavior, flash profiles, microhardness, microstructure at the welding interface, and tensile properties of the joints were evaluated under various welding conditions. The results indicated that flash symmetry was lower along the oscillation direction and higher perpendicular to it. Short-side oscillation produced more homogeneous flash ejection compared to long-side oscillation. No distinct softening zones were observed in the hardness profiles of the LFWed T-joints. The microstructure at the welding interface consisted of martensite, bainite, and ferrite, indicating that the weld region reached temperatures above the A₁ temperature. The martensite fraction and hardness increased with higher upset and applied pressure after oscillation. Tensile tests revealed 100 % joint efficiency across all welding conditions, with ductile fracture occurring in the base metal due to the absence of welding defects and increased hardness at the interface.

线性摩擦焊（LFW）是一种成熟的固态连接技术。然而，它在 T 型接头结构中的应用仍有待探索。本研究使用低碳钢 SM490A 研究了焊接参数对线性摩擦焊接（LFWed）T 型接头的影响，如摆动方向、镦粗和摆动后施加的压力。在不同的焊接条件下，对接头的飞溅行为、飞溅轮廓、显微硬度、焊接界面的显微组织和拉伸性能进行了评估。结果表明，沿振荡方向的闪光对称性较低，而垂直于振荡方向的闪光对称性较高。与长边振荡相比，短边振荡产生的闪光喷射更均匀。在低频焊接 T 型接头的硬度曲线上没有观察到明显的软化区。焊接界面的微观结构由马氏体、贝氏体和铁素体组成，表明焊接区域的温度高于 A1 温度。马氏体的比例和硬度随着振荡后更大的扰动和施加压力而增加。拉伸试验表明，在所有焊接条件下，接头效率都达到了 100%，由于没有焊接缺陷和界面硬度增加，母材发生了韧性断裂。

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引用次数: 0

Joining by forming of bi-material collector coins with rotating elements 以成型方式连接带有旋转元件的双材料收藏硬币

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100265

Pedro M.S. Rosado , Rui F.V. Sampaio , João P.M. Pragana , Ivo M.F. Bragança , Carlos M.A. Silva , Paulo A.F. Martins

This paper presents a novel manufacturing process for producing innovative bi-material collector coins with free-rotating inner elements. The inner elements are fabricated using additive manufacturing, enabling the creation of coins with complex and intricate geometric details that would be unattainable using conventional wrought materials. The outer elements (rings) are metallic, and this study addresses the challenge of securely connecting them to the inner elements through force-closed mechanisms formed during the coin minting process. Finite element modeling, combined with experimentation on bi-material (polymer-metal and metal-metal) coins, is employed to analyze material flow, assess minting forces, and evaluate contact pressures at the force-closed joints. The analysis ensures that adequate destructive forces are required to separate the inner elements from the rings and provides insights into selecting the appropriate process parameters for simultaneous coining and joining. The successful production of the first bi-material collector coin prototypes with free-rotational inner elements validates the overall development.

本文介绍了一种新颖的制造工艺，用于生产具有自由旋转内部元素的创新型双材料收藏硬币。内部元件采用增材制造工艺制造，因此能制造出具有复杂和错综复杂几何细节的硬币，而传统的锻造材料是无法实现这些细节的。外部元件（环）是金属的，本研究要解决的难题是如何通过硬币铸造过程中形成的力闭合机制将它们与内部元件安全地连接起来。有限元建模与双材料（聚合物-金属和金属-金属）硬币实验相结合，用于分析材料流动、评估铸造力，以及评估力闭合连接处的接触压力。该分析确保需要足够的破坏力才能将内部元件与圆环分离，并为选择适当的工艺参数以同时进行铸币和接合提供了启示。首枚带有自由旋转内部元件的双材料收藏硬币原型的成功生产验证了整个开发过程。

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引用次数: 0

Influence of the material properties on the clinching process and the resulting load-bearing capacity of the joint 材料特性对夹紧过程和由此产生的接头承重能力的影响

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100263

Christian Steinfelder, Dennis Rempel, Alexander Brosius

This study focuses on the phenomenological change in material strength caused by a specific heat treatment and the subsequent analysis of the influence on the clinching process and the resulting joint properties. For this purpose, three series of tests were performed. In the first series of tests, the influence of heat treatment up to 340 °C on the mechanical properties of an age-hardenable AlMgSi alloy was investigated. Holding time and temperature were varied and the material strength was evaluated by tensile and hardness tests. Two strength-increasing and two strength-reducing heat treatment parameters were identified. In the second series of tests, selected heat treatment parameters were applied to a larger number of specimens and the joint strength was investigated by shear and head tensile tests. In the shear tensile test, mainly the properties of the punch-side material have an influence on the resulting joint strength. A change in strength of the die-side material can be neglected. In contrast, the properties of both sheets are important in the head tensile test. The strength of the joint will only increase if the strength of both sheets is increased. In general, a strength increasing heat treatment resulted in higher joint strength. In the third series of tests, the factor of punch displacement was considered, which was demonstrated to directly influence the formation of the clinched joint geometry.

本研究的重点是特定热处理对材料强度造成的现象变化，以及随后对夹紧过程和由此产生的接头性能的影响分析。为此，我们进行了三个系列的测试。在第一个系列试验中，研究了最高温度为 340 °C 的热处理对时效硬化铝镁硅合金机械性能的影响。改变了保温时间和温度，并通过拉伸和硬度测试评估了材料强度。确定了两个提高强度和两个降低强度的热处理参数。在第二系列试验中，对更多试样采用了选定的热处理参数，并通过剪切和头部拉伸试验研究了接头强度。在剪切拉伸试验中，主要是冲头侧材料的特性对接头强度产生影响。模具侧材料强度的变化可以忽略不计。相反，在封头拉伸试验中，两张板材的特性都很重要。只有同时提高两片板材的强度，接头的强度才会提高。一般来说，增加强度的热处理可提高接头强度。在第三系列试验中，考虑了冲头位移的因素，结果表明冲头位移直接影响咬合接头几何形状的形成。

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引用次数: 0

Enhancement of joint quality for laser welded dissimilar material cell-to-busbar joints using meta model-based multi-objective optimization 利用基于元模型的多目标优化技术提高激光焊接异种材料电池-母线接头的接头质量

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100261

Andreas Andersson Lassila, Tobias Andersson, Rohollah Ghasemi, Dan Lönn

In the battery pack assembly, it is essential to ensure that the cell-to-busbar joints can be produced with high quality and with minimal impact on the individual battery cells. This study examines the influence of process parameters on the joint quality for nickel-plated copper and steel plates, laser welded in an overlap configuration. Artificial neural network-based meta models, trained on numerical results from computational fluid dynamics simulations of the laser welding process, are used to predict and evaluate the joint quality. A set of optimized process parameters is identified, in order to simultaneously maximize the interface width for the joints, and minimize the formation of undercuts and in-process temperatures. In an meta model-based multi-objective optimization approach, the non-dominated sorting genetic algorithm II (NSGA-II) is used to efficiently search for trade-off solutions and the meta models are used for objective approximation. As a result, the objective evaluation time is decreased from around 9 h, when evaluated directly from numerical simulations, to only tenths of a second. From the Pareto-optimal front of trade-off solutions, three optimal solutions are selected for validation. The selected solutions are validated through laser welding experiments and numerical simulations, resulting in joints with large interface widths and low in-process temperatures without a full penetration.

在电池组组装过程中，必须确保电池单元与母线的连接质量高，并且对单个电池单元的影响最小。本研究探讨了工艺参数对重叠配置激光焊接镀镍铜板和钢板接头质量的影响。基于人工神经网络的元模型是在激光焊接过程的计算流体动力学模拟数值结果的基础上训练而成的，用于预测和评估接头质量。确定了一组优化的工艺参数，以便同时最大限度地增加接头的界面宽度，并最大限度地减少缺口的形成和降低加工过程中的温度。在基于元模型的多目标优化方法中，非支配排序遗传算法 II (NSGA-II) 被用来高效地搜索折衷解决方案，元模型被用来进行目标近似。因此，目标评估时间从直接从数值模拟评估的约 9 小时缩短到仅十分之一秒。从权衡解决方案的帕累托最优前沿中，选出三个最优解决方案进行验证。所选方案通过激光焊接实验和数值模拟进行了验证，结果是接头界面宽度大，加工过程温度低，且没有完全熔透。

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引用次数: 0

Laser welding thermal analysis of 20mm-thick EH40 steel with gap through an equivalent thermal conductivity method 通过等效导热法对有间隙的 20mm 厚 EH40 钢进行激光焊接热分析

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100266

Guolong Zhang , Yu Huang , Xuanrui Liu , Hui Wang , Youmin Rong , Yifan Peng , Jiajun Xu

Laser welding of thick plates is extremely sensitive to the gap between joints. With the same laser welding parameters, slight adjustment of the gap can lead to different weld morphologies. An appropriate joint gap is conducive to increasing the penetration depth and reducing defects. To investigate the influence of the gap between butt joints on the penetration depth during single-pass laser welding of 20 mm thick EH40 steel, five groups of experiments were conducted with a laser power of 15 kW and a welding speed of 10mm/s, and gap sizes ranging from 0 to 0 .4mm. A finite element model of the temperature field was established for the experimental samples. Using the concept of equivalent substitution, the heat transfer process was used to replace the downward flow of the molten pool along the gap, and the equivalent thermal conductivity was derived to predict the penetration depth under different gap sizes. The results showed that within the gap range of 0–0.3 mm, the penetration depth increased and spatter decreased as the gap increased. When the gap exceeded 0.2 mm, weld depression began to appear. The maximum penetration depth of 19.33 mm was achieved when the gap was 0 .3mm. When the gap reached 0.4 mm, unacceptable severe collapse occurred in the weld. Additionally, the accuracy of the temperature field simulation results was verified by the experimental results.

激光焊接厚板对焊点之间的间隙极为敏感。在相同的激光焊接参数下，间隙的细微调整会导致不同的焊接形态。适当的焊点间隙有利于增加熔深和减少缺陷。为了研究单程激光焊接 20 毫米厚 EH40 钢时对接接头间隙对熔透深度的影响，在激光功率为 15 千瓦、焊接速度为 10 毫米/秒、间隙大小为 0 至 0.4 毫米的条件下进行了五组实验。为实验样品建立了温度场有限元模型。利用等效替代的概念，用传热过程替代熔池沿间隙向下流动的过程，得出等效导热系数，从而预测不同间隙尺寸下的熔透深度。结果表明，在 0-0.3 毫米的间隙范围内，随着间隙的增大，穿透深度增加，飞溅减少。当间隙超过 0.2 毫米时，开始出现焊接凹陷。当间隙为 0.3 毫米时，最大熔深为 19.33 毫米。当间隙达到 0.4 毫米时，焊缝出现了无法接受的严重塌陷。此外，实验结果也验证了温度场模拟结果的准确性。

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引用次数: 0

Characterization of physical metallurgy of quenching and partitioning steel in pulsed resistance spot welding: A simulation-aided study 脉冲电阻点焊中淬火和分区钢的物理冶金特性：模拟辅助研究

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100264

Ali Bahmani, Vahid Feizollahi, Rouholah Ashiri

This study mainly focuses on the microstructure evolution of QP980 steel during resistance spot welding and its influence on the mechanical performance of resistance spot welds which is a critical influencing factor on the quality of body-in-white at the service condition. It is observed that the thermomechanically engineered microstructure of QP980 steel changes to form metastable phases such as martensite in the fusion zone and the heat affected zone due to rapid cooling induced by the thermal cycle of the welding. A finite element modeling of the welding process was used to predict the weldment heat distribution, thermal history and microstructure evolution in different welding zones. The modeled thermal history of the weldments shows that the peak temperature in the four-pulse resistance spot welding is delayed because of pulsed welding conditions and holding times between the welding pulses. This heat management approach in pulsed welding prevents void formation. The modeled thermal history and rapid heating, and cooling conditions are discussed here to predict the microstructure evolution and transformation in the fusion and reheated zones. The modeled results were helpful in the prediction of the microstructure at different weld zones. Then the strategic links between the microstructure and mechanical performance of the welded alloy are discussed thoroughly. The microhardness profile of the weld is discussed from a microstructural point of view to disclose the physical metallurgy of the welds. Softening phenomena were not observed in the sub-critical heat affected zone.

本研究主要关注 QP980 钢在电阻点焊过程中的微观结构演变及其对电阻点焊机械性能的影响，而机械性能是白车身在使用状态下质量的关键影响因素。研究发现，由于焊接热循环引起的快速冷却，QP980 钢的热机械工程微观结构发生了变化，在熔合区和热影响区形成了马氏体等易变相。焊接过程的有限元模型用于预测不同焊接区的焊接热分布、热历史和微观结构演变。焊接件的热历史模型显示，由于脉冲焊接条件和焊接脉冲之间的保持时间，四脉冲电阻点焊的峰值温度被延迟。脉冲焊接中的这种热量管理方法可防止空洞的形成。本文讨论了模型热历史、快速加热和冷却条件，以预测熔合区和再加热区的微观结构演变和转变。模型结果有助于预测不同焊接区的微观结构。然后深入讨论了焊接合金的微观结构与机械性能之间的战略联系。从微观结构的角度讨论了焊缝的显微硬度曲线，以揭示焊缝的物理冶金学。在亚临界热影响区未观察到软化现象。

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引用次数: 0

A comprehensive techno-economic and environmental comparison of plasma-treated adhesive-bonded thermoplastic composites 等离子体处理的粘合剂粘结热塑性复合材料的技术经济和环境综合比较

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100268

Chiara Mandolfino, Lucia Cassettari, Marco Pizzorni, Luigi Benvenuto, Enrico Lertora

Thermoplastic composites are gaining attention for their ability to support a circular economy, shifting away from traditional cost-driven design. Unlike thermoset composites, commonly used in automotive and aerospace sectors, thermoplastic composites offer recyclability, promoting environmental and economic sustainability. Adhesive bonding in thermoplastic composites provides even stress distribution, maintaining structural integrity and reducing delamination risks, which is crucial for lightweight design in transport and renewable energy applications. Optimising adhesive bonded joints is essential to improve structural integrity, efficiency and sustainability. This involves balancing technical, economic and environmental factors, with surface preparation, plasma treatment in particular, playing a key role.

This paper provides a comprehensive techno-economic-environmental comparison of adhesive bonded joints. The study integrates cost-effectiveness, production efficiency and environmental impact assessments to guide informed decision-making. The methodology includes preparing substrates with low-pressure plasma surface treatments, forming adhesive-bonded joints with different adhesives, and optimising process parameters using Response Surface Methodology (RSM). A Life Cycle Assessment (LCA) on optimised scenarios enhances Tensile Shear Strength (TSS). The study concludes with a comprehensive comparison, offering insights for resilient, efficient and sustainable engineering solutions.

热塑性复合材料能够支持循环经济，摆脱传统的成本驱动型设计，因而备受关注。与汽车和航空航天领域常用的热固性复合材料不同，热塑性复合材料具有可回收性，促进了环境和经济的可持续发展。热塑性复合材料中的粘合剂粘接可提供均匀的应力分布，保持结构完整性并降低分层风险，这对于运输和可再生能源应用领域的轻量化设计至关重要。优化粘合接头对于提高结构完整性、效率和可持续性至关重要。这涉及到技术、经济和环境因素之间的平衡，其中表面处理，尤其是等离子处理起着关键作用。该研究综合了成本效益、生产效率和环境影响评估，为明智决策提供指导。研究方法包括用低压等离子表面处理技术制备基材，用不同的粘合剂形成粘合接头，以及使用响应面方法（RSM）优化工艺参数。对优化方案进行生命周期评估（LCA），以提高拉伸剪切强度（TSS）。研究最后进行了综合比较，为弹性、高效和可持续的工程解决方案提供了启示。

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引用次数: 0

Improving the joint strength of thermoplastic composites joined by press joining using laser-based surface treatment 利用激光表面处理技术提高热塑性复合材料的接合强度

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100260

Alexander Liebsch , Daniel Wohlfahrt , Thomas Kuntze , Levin Schilling , Jana Gebauer , Robert Kupfer , Niels Modler , Andrés Fabián Lasagni , Maik Gude

Fibre-reinforced thermoplastic composites (TPC) provide an automated and cost-effective solution for their use in lightweight structures in series production. The combination of different material configurations allows the design of highly stress tolerant components. Previous studies demonstrated that the combination of TPC sheets, TPC hollow profiles and injection moulding compounds is even suitable for crash-relevant automotive parts. All three components are combined during the injection moulding process. To prevent collapse, the part must remain in a consolidated state and cannot be preheated. However, this results in poor adhesion between the hollow profile, the bulk material, and the TPC sheet. Previous studies have shown that the bonding strength between the hollow profile and the injection moulding compound can be increased by surface pre-treatment using laser structuring and plasma technology. In this work, laser structuring is employed to enhance the bonding strength between the hollow profile and the TPC sheet. Microscopy analysis is used to investigate the resulting surface morphology. Subsequently, single-lap-shear (SLS) specimens are produced by pressing the TPC sheets onto the flat part. The resulting bonding strengths are then evaluated by tensile shear tests. The study analyses the impact of various pre-treatment parameters on the bonding strength. Furthermore, it investigates the effect of sheet temperature on the bonding strength, including specimens without pre-treatment. Finally, the results of the surface treatment of hollow composite profiles are discussed.

纤维增强热塑性复合材料（TPC）为轻质结构的批量生产提供了自动化和经济高效的解决方案。将不同的材料配置组合在一起，可以设计出具有高度应力承受能力的部件。先前的研究表明，TPC 板材、TPC 中空型材和注塑化合物的组合甚至适用于与碰撞有关的汽车部件。在注塑成型过程中，这三种成分会结合在一起。为防止塌陷，部件必须保持固结状态，且不能预热。然而，这会导致中空型材、散装材料和 TPC 片材之间的粘合力较差。以往的研究表明，通过使用激光成型和等离子技术进行表面预处理，可以提高中空型材与注塑模具之间的粘合强度。在这项工作中，采用了激光成型技术来提高中空型材与 TPC 板材之间的粘合强度。显微镜分析用于研究由此产生的表面形态。随后，通过将 TPC 片材压到平面部件上，制作出单层剪切（SLS）试样。然后通过拉伸剪切试验评估粘接强度。研究分析了各种预处理参数对粘接强度的影响。此外，还研究了板材温度对粘接强度的影响，包括未进行预处理的试样。最后，还讨论了空心复合材料型材表面处理的结果。

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引用次数: 0

Investigation of the electrical quality and long-term stability of aluminum ground stud connections in automotive applications 汽车应用中铝接地螺栓连接的电气质量和长期稳定性调查

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-10-16 DOI: 10.1016/j.jajp.2024.100262

Viktor Haak, Keke Yang, Gerson Meschut

The rapid advancement in the electrification of modern vehicles has led to a continuous increase in electrical consumers for various comfort and safety functions. Ground studs serve as the electrical interface between the conductive vehicle body and the onboard network. Drawn arc stud welding is an economical and established joining process for producing ground stud joints. The circuits in the onboard network are increasingly subject to greater demands regarding current-carrying capacity and long-term stability. Reliable signal and power transmission require minimal contact resistance at the electrical connection points of the ground stud system and must withstand various operating and environmental conditions over the entire service life. In this study, a ground stud made of AlMg5, with a ZnNi-coated steel cap nut was used on a 2.0 mm thick sheet of AlMg3. The electrical connection of the ground studs was made using tinned copper cable lugs and 35 mm² cables. To analyze the electrical resistance behavior in an accelerated test, the ground studs were subjected to a superimposed load with a cyclic current profile for 1008 h under changing climatic conditions. The results show that under the chosen operational and environmental conditions, accelerated aging and intermittent resistance behavior occur. A characteristic drop in resistance during the test indicates the failure point of the electrical connection. The cause of failure can be attributed to media penetration into the electrical contact zone. A failure of the electrical connection was observed after 512 h.

随着现代汽车电气化的快速发展，用于各种舒适和安全功能的用电量不断增加。接地螺栓是导电车身与车载网络之间的电气接口。拉弧螺柱焊接是生产接地螺柱接头的一种经济、成熟的连接工艺。车载网络中的电路对载流能力和长期稳定性的要求越来越高。可靠的信号和电力传输要求接地螺柱系统电气连接点的接触电阻最小，并且必须在整个使用寿命期间经受住各种操作和环境条件的考验。在这项研究中，在 2.0 毫米厚的 AlMg3 板上使用了由 AlMg5 制成的接地螺柱，该螺柱带有一个 ZnNi 涂层钢帽螺母。接地螺栓的电气连接使用镀锡铜电缆耳和 35 mm² 电缆。为了分析加速试验中的电阻行为，接地螺栓在不断变化的气候条件下承受了 1008 小时的周期电流曲线叠加负载。结果表明，在选定的操作和环境条件下，会出现加速老化和间歇性电阻行为。测试期间电阻下降的特征表明了电气连接的故障点。故障原因可能是介质渗入电气接触区。512 小时后观察到电气连接失效。

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引用次数: 0

Effects of triflute pin geometry on defect formation and material flow in FSW using CEL approach 使用 CEL 方法分析三楔销几何形状对 FSW 中缺陷形成和材料流动的影响

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-10-10 DOI: 10.1016/j.jajp.2024.100259

Mostafa Akbari , Parviz Asadi

Complicated tool pin designs in Friction Stir Welding (FSW) need to be considered in terms of material flow and defect formation. This study investigates the effects of the triflute tool's geometrical parameters on temperature, strain, void formation, and material mixing using a numerical method. The numerical model employs a coupled Eulerian-Lagrangian (CEL) formulation and successfully predicts void formation and material mixing during friction stir welding (FSW). Four tool pin designs are considered for material flow, including one cylindrical pin and three triflute pins with flute radii of 1 mm, 1.5 mm, and 2 mm. The findings indicate that the stir zone is divided into shoulder-driven and pin-driven zones, each exhibiting distinct material flow patterns. In the shoulder-driven zone, material flow toward the advancing side is dominant, while in the pin-driven zone, it flows toward the retreating side. Flutes on the FSW pin tool increase the sweeping rate, strain, and material movement in the stir zone. However, flutes with a larger radius sweep a greater amount of material and thus require more softened material to facilitate movement. Therefore, for defect-free joint formation, a higher rotational speed of the tool will be required, which may adversely affect tool lifespan and joint mechanical properties. The effectiveness of flutes with a smaller radius of 1 mm is significantly greater than that of those with a larger radius (1.5 or 2 mm) in enhancing material flow and achieving defect-free welding.

搅拌摩擦焊接（FSW）中复杂的工具销钉设计需要考虑材料流动和缺陷形成。本研究采用数值方法研究了三楔形工具的几何参数对温度、应变、空洞形成和材料混合的影响。数值模型采用欧拉-拉格朗日（CEL）耦合公式，成功预测了搅拌摩擦焊（FSW）过程中的空洞形成和材料混合。在材料流动方面，考虑了四种工具销钉设计，包括一个圆柱销钉和三个三楞销钉，其楞半径分别为 1 毫米、1.5 毫米和 2 毫米。研究结果表明，搅拌区分为肩部驱动区和销轴驱动区，每个区都表现出不同的材料流动模式。在肩部驱动区，材料主要流向前进的一侧，而在销钉驱动区，材料则流向后退的一侧。FSW 针工具上的凹槽增加了搅拌区的扫描速度、应变和材料运动。然而，半径较大的凹槽会扫过更多的材料，因此需要更多的软化材料来促进运动。因此，为了形成无缺陷的接缝，需要提高工具的旋转速度，这可能会对工具的使用寿命和接缝的机械性能产生不利影响。在增强材料流动和实现无缺陷焊接方面，半径较小的凹槽（1 毫米）的效果明显优于半径较大的凹槽（1.5 毫米或 2 毫米）。

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引用次数: 0