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Temperature and material flow in one-step double-acting friction stir welding process of aluminum alloy: Modeling and experimental

Mechanical Engineering for Society and Industry · Vol. 5 No. 1 (2025) · hlm. 145–157

DOI
10.31603/mesi.12987
ISSN
2798-5245
Terbit
2025-04-15
Penerbit
Universitas Muhammadiyah Magelang
Bahasa
en

Abstrak

Aluminum, known for its lower density compared to steel, is widely used in various applications. Welding is often required to form aluminum into technical structures. However, when fusion welding is used, it can lead to porosity in the weld. This occurs due to the significant difference in hydrogen gas solubility between liquid and solid aluminum, which traps hydrogen gas within the weld metal. Friction Stir Welding (FSW), a solid-state welding technique, has been proven to minimize porosity. However, for thick structures, FSW poses challenges, as welding must be done on both sides, increasing the welding time. To overcome this limitation, FSW has been modified into a one-step double-side FSW process, where two tools simultaneously work on both surfaces of the workpiece. This creates a unique condition with two heat sources and two stirring motion sources. To understand the temperature distribution and material flow in this process, modeling was conducted using Computational Fluid Dynamics (CFD). The upper and lower tools in the one-step double-side FSW process operate under identical conditions: a rotation speed of 1500 rpm, a welding speed of 30 mm/min, and a tilt angle of 0 degrees. The aluminum plate is treated as fluid, while the tools are considered solid in the model. The results of the temperature distribution modeling were validated against published studies, and the material flow was verified through macro- and microstructural observations of the cross-section. The validation showed that the model is accurate, with an error of only 4.07%.

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  • Sebelas Maret University
  • Islamic University of Madinah
  • Diponegoro University
  • Universitas Raharja
  • State University of Semarang
  • Universitas PGRI Sumatera Barat
  • Leiden University
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Rekan penulisOrganisasiArtikel bersama
Yuli Prasetyo AdhiDiponegoro University2
Muhyidin MuhyidinDiponegoro University2
Sohaib Z. KhanIslamic University of Madinah2
Hamad AlMohamadiIslamic University of Madinah2
Muhamad Dwi SeptiyantoSebelas Maret University2
Syamsul HadiSebelas Maret University2
Untung RahardjaUniversitas Raharja1
Fitri AndriyaniUniversitas Raharja1
Yuli Prasetyo AdhiAfiliasi tidak diketahui1
Rahmawati Mohd YusoffAfiliasi tidak diketahui1
Dewi SulistianingsihState University of Semarang1
Puji Novita SariAfiliasi tidak diketahui1
Sari LestariAfiliasi tidak diketahui1
Suryadi SuryadiLeiden University1
Nurul Aina KotoUniversitas PGRI Sumatera Barat1
Asad Ali ZaidiHarbin Engineering University1
Muhammad Nihal NaseerNational University of Sciences and Technology1
Abdulrahman AljabriIslamic University of Madinah1
Meshal AljohaniKing Abdulaziz City for Science and Technology1
Rashid ShamsuddinUniversiti Teknologi Petronas1
Satria AuliansyahSebelas Maret University1
Naufal Rizky SayyidSebelas Maret University1
Indri YaningsihSebelas Maret University1
Rian FirmandaSebelas Maret University1
Essam R.I. MahmoudIslamic University of Madinah1
TriyonoSebelas Maret University1
Irfan SantosaUniversitas Pancasakti Tegal1
Solikin AndriyantoSebelas Maret University1
Wega TrisunaryantiUniversitas Gadjah Mada1
Oberlin SidjabatAfiliasi tidak diketahui1

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Sumber metadata: OAI-PMH (metadata jurnal) https://journal.unimma.ac.id/index.php/mesi/oai, pertama di-harvest 9 Nov 2026, terakhir terlihat 9 Nov 2026.
Metadata asli (oai_dc) 
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	<dc:title xml:lang="en">Temperature and material flow in one-step double-acting friction stir welding process of aluminum alloy: Modeling and experimental</dc:title>
	<dc:creator xml:lang="en">Budiana, Eko Prasetya</dc:creator>
	<dc:creator xml:lang="en">Hapsari, Sekar Gading Happy</dc:creator>
	<dc:creator xml:lang="en">Mahmoud, Essam R. I.</dc:creator>
	<dc:creator xml:lang="en">Triyono, Triyono</dc:creator>
	<dc:subject xml:lang="en">One-step double-side FSW</dc:subject>
	<dc:subject xml:lang="en">Aluminum</dc:subject>
	<dc:subject xml:lang="en">Material flow</dc:subject>
	<dc:subject xml:lang="en">Temperature distribution</dc:subject>
	<dc:subject xml:lang="en">Modeling</dc:subject>
	<dc:description xml:lang="en">Aluminum, known for its lower density compared to steel, is widely used in various applications. Welding is often required to form aluminum into technical structures. However, when fusion welding is used, it can lead to porosity in the weld. This occurs due to the significant difference in hydrogen gas solubility between liquid and solid aluminum, which traps hydrogen gas within the weld metal. Friction Stir Welding (FSW), a solid-state welding technique, has been proven to minimize porosity. However, for thick structures, FSW poses challenges, as welding must be done on both sides, increasing the welding time. To overcome this limitation, FSW has been modified into a one-step double-side FSW process, where two tools simultaneously work on both surfaces of the workpiece. This creates a unique condition with two heat sources and two stirring motion sources. To understand the temperature distribution and material flow in this process, modeling was conducted using Computational Fluid Dynamics (CFD). The upper and lower tools in the one-step double-side FSW process operate under identical conditions: a rotation speed of 1500 rpm, a welding speed of 30 mm/min, and a tilt angle of 0 degrees. The aluminum plate is treated as fluid, while the tools are considered solid in the model. The results of the temperature distribution modeling were validated against published studies, and the material flow was verified through macro- and microstructural observations of the cross-section. The validation showed that the model is accurate, with an error of only 4.07%.</dc:description>
	<dc:publisher xml:lang="en">Universitas Muhammadiyah Magelang</dc:publisher>
	<dc:date>2025-04-15</dc:date>
	<dc:type>info:eu-repo/semantics/article</dc:type>
	<dc:type>info:eu-repo/semantics/publishedVersion</dc:type>
	<dc:format>application/pdf</dc:format>
	<dc:identifier>https://journal.unimma.ac.id/mesi/article/view/12987</dc:identifier>
	<dc:identifier>10.31603/mesi.12987</dc:identifier>
	<dc:source xml:lang="en">Mechanical Engineering for Society and Industry; Vol. 5 No. 1 (2025); 145-157</dc:source>
	<dc:source>2798-5245</dc:source>
	<dc:language>en</dc:language>
	<dc:relation>https://journal.unimma.ac.id/mesi/article/view/12987/5829</dc:relation>
	<dc:rights xml:lang="en">Copyright (c) 2025 Triyono Triyono, Eko Prasetya Budiana, Essam R. I. Mahmoud, Sekar Gading Happy Hapsari</dc:rights>
</oai_dc:dc>