Friction stir welding of AA6082 and AA5083 T-joints for naval applications: Finite element modeling and experimental analysis of material flow

This study investigates the influence of rotational speed on material flow during friction stir welding (FSW) of dissimilar aluminum T-joints made of AA6082 and AA5083 alloys for naval applications. A finite element (FE) model was used to simulate the thermomechanical behavior and visualize the material flow during the welding process. Simulations were carried out at two rotational speeds, 500 rpm and 900 rpm, to evaluate their effects on heat distribution, strain rate and deformation patterns. The numerical results show that higher speeds improve plasticization and material mixing but also increase the risk of defect formation due to excessive heat input. The simulation outcomes are confirmed by the experimental observations made in the previous study, particularly with regards to the formation of heat-affected zones (HAZ) associated with the microhardness variations.