In order to predict dissimilar materials’ flow behavior during friction stir welding, a morphological simulation of the weldment was performed using Level Set (LS) method. Thermal and computational fluid dynamics (CFD) simulations were conducted to calculate the temperature distribution and material flow velocity during the welding process. Level set model was created to predict the weld morphology based on CFD results. Weld morphologies in different tool rotational speeds, offsets position and height levels of the specimen were simulated. In order to validate the simulations, temperature measurements, optical microscopy (OM) of the weldment and scanning electron microscopy (SEM) of the stirred zone (SZ) were carried out. It was seen that the main cause of defects in the weld zone were steel particles detached in aluminum matrix. The simulation results revealed that increasing rotational speed and offset through the steel side could generate more steel particles. Also, the particles were more in the top height level of the weld section than in the middle and bottom levels.

为了预测搅拌摩擦焊接期间不同材料的流动行为，使用水平集（LS）方法对焊件进行了形态模拟。进行了热和计算流体动力学（CFD）仿真，以计算焊接过程中的温度分布和材料流速。创建水平集模型以基于CFD结果预测焊缝形态。模拟了不同工具转速，试样的偏移位置和高度水平下的焊接形态。为了验证模拟效果，进行了温度测量，焊件的光学显微镜（OM）和搅拌区（SZ）的扫描电子显微镜（SEM）。可以看出，焊接区缺陷的主要原因是钢颗粒从铝基体中分离出来。仿真结果表明，提高旋转速度和通过钢侧的偏移会产生更多的钢颗粒。而且，在焊接部分的最高高度水平比在中间和最低水平水平上的颗粒更多。