Friction Stir Welding Process of 5083/6061 Dissimilar Aluminum Alloys for New Energy Battery Trays

HUANG Xiangshan; MENG Yuchi; ZHAO Yan; ZENG Yang; LI Nengwen; ZHAO Yanjun

doi:10.3969/j.issn.1674-6457.2025.09.010

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (9) : 103-114. DOI: 10.3969/j.issn.1674-6457.2025.09.010

Light Alloy Forming

Friction Stir Welding Process of 5083/6061 Dissimilar Aluminum Alloys for New Energy Battery Trays

HUANG Xiangshan^1,2, MENG Yuchi^3a*, ZHAO Yan^3a, ZENG Yang^3a, LI Nengwen^3a, ZHAO Yanjun^3a,3b*

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Abstract

The work aims to study the effect of different welding parameters on the microstructure and properties of 5083/6061 dissimilar aluminum alloy FSW joints. Friction stir welding was carried out on 5083/6061 dissimilar aluminum alloy plates under welding parameters of 100 and 200 mm/min and stirring head rotation speeds of 600, 900 and 1 200 r/min. The microstructure and mechanical properties of the welded joints under different welding process parameters were analyzed. With the ABAQUS software and based on the coupled Euler-Lagrange (CEL) method, the temperature and strain distribution of the welding process were analyzed by finite element simulation. With the increase of the rotation speed, both the peak temperature and the maximum strain value at the joint gradually increased. The high-temperature and high-strain zones with conical distribution were all on the advancing side (5083). As the welding speed increased from 100 mm/min to 200 mm/min, the fluidity of the metal at the weld seam decreased, the size of the nugget zone (NZ) reduced, and the joint performance was significantly improved. The nugget zone underwent plastic deformation and dynamic recrystallization under the action of heat-force coupling and welding thermal cycling, forming dense fine equiaxed grains. The thermo-mechanically affected zone (TMAZ) was subject to mechanical stirring and thermal cycling, during which grains were elongated and refined, forming a gradient of grain change from fragmented structure to strip-like structure. The heat affected zone (HAZ) was only affected by the welding thermal cycle, with a relatively low equivalent plastic strain (PEEQ) and grain coarsening in the region. Under different welding parameters, the microhardness of the joint showed a "W"-shaped distribution. The minimum hardness at the joint and the fracture position both occurred in the heat-affected zone of the recloser side (RS) 6061. When the welding speed is 200 mm/min and the stirring head rotation speed is 900 r/min, the joint performance is optimal, with a tensile strength of 211.6 MPa (equivalent to 75.6% of the 6061 base material) and an elongation of 10.3%.

Key words

friction stir welding / finite element modelling / dissimilar aluminum alloys / microstructure / mechanical property

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HUANG Xiangshan, MENG Yuchi, ZHAO Yan, ZENG Yang, LI Nengwen, ZHAO Yanjun. Friction Stir Welding Process of 5083/6061 Dissimilar Aluminum Alloys for New Energy Battery Trays[J]. Journal of Netshape Forming Engineering. 2025, 17(9): 103-114 https://doi.org/10.3969/j.issn.1674-6457.2025.09.010

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Funding

Nanning Science and Technology Development Project (20231026); Special Fund for Science and Technology Development of Guangxi (AD25069078); The National Natural Science Foundation of China (51661004)