| Abstract Scope |
This paper presents a novel approach to optimizing Friction Stir Welding (FSW) processes through a mathematical model that calculates optimal temperatures and forces based on material properties. It delves into the mechanisms of heat generation and material flow, examining the exchange between friction-induced deformation and heat transfer. Applying principles of fluid dynamics, the model focuses on refining process parameters and adopts scaling laws to enhance accuracy. It introduces a unique geometric methodology to estimate the critical temperature at the external limit of shear layer zone, integrating factors like strain rate, stress, and heat. The model also innovatively adjusts plunging force by calculating the torque factor by minimizing the logarithm square error of temperature and torque. Validation is carried out through a comprehensive review of existing literature, confirming the model's applicability across a range of materials. The outcomes include essential formulas for predicting process parameters, addressing significant FSW challenges. This research facilitates advanced implementation in critical sectors such as aerospace manufacturing, targeting the most efficient welding parameters and promoting the broader adoption and effectiveness of FSW. |