Numerical Modelling of Temperature Distribution and Defect Prediction during Friction Stir Welding of Aluminum Alloy

In this study, a coupled Eulerian-Lagrangian approach was developed to model the friction stir welding process of aluminum alloy AA 7075, aiming to analyze the distribution of temperature and predict defect formation during the process. The precision of the model was validated by comparing its results with findings from previous studies and by examining weld images. The findings indicate a symmetrical temperature distribution along the welding path. Additionally, the analysis highlighted V-shaped asymptotic patterns with steep temperature gradients in the weld zone after full immersion. Notably, when a tilt angle of 2° was applied, no defects were observed.