Tungsten inert gas (TIG) welding is the most commonly used joining process for aluminum alloy for AA6061 and AA7075 which are highly demanded in the aerospace engineering and the automobile sector, but there are some defects occur during TIG welding like micro-crack, coarse grain structure, and porosity. To improve these defects, the TIG welded joint is processed using friction stir processing (FSP).

This paper presents the effect of friction stir processing on TIG welding with filler ER4043 and ER 5356 for dissimilar aluminum alloy AA6061 and AA7075. The mechanical characterization, finite element formulation and mathematical equations of heat transfer of TIG + FSP welded joints are investigated using ANSYS Fluent software by adjusting process parameters of FSP. The results show that the maximum compressive residual stress 73 MPa was obtained at the fusion zone (FZ) of the TIG weldment with filler ER4043, whereas minimum compressive residual stress 37 MPa was obtained at stir zone (SZ) of the TIG + FSP with filler 5356. The maximum heat flux 5.33 × 106 W/m2 and temperature 515 °C have observed at tool rotation 1600 rpm with a feed rate of 63 mm/min. These results give a satisfactory measure of confidence in the fidelity of the simulation

钨极惰性气体保护（TIG）焊接是AA6061和AA7075铝合金的最常用焊接工艺，在航空航天工程和汽车领域要求很高，但是在TIG焊接过程中会出现一些缺陷，例如微裂纹，粗大晶粒结构和孔隙率。为了改善这些缺陷，TIG焊接接头采用摩擦搅拌工艺（FSP）进行加工。

本文介绍了摩擦搅拌工艺对用于不同铝合金AA6061和AA7075的填充剂ER4043和ER 5356的TIG焊接的影响。利用ANSYS Fluent软件，通过调整FSP的工艺参数，研究了TIG + FSP焊接接头的力学特性，有限元公式和传热数学方程。结果表明，在填充有ER4043的TIG焊件的熔合区（FZ）处获得的最大压缩残余应力为73 MPa，而在填充有TIG + FSP的搅拌区（SZ）处获得的最小压缩残余应力为37 MPa 5356.在工具转速1600 rpm和进给速度63 mm / min的条件下，观察到最大热通量为5.33×106 W / m2，温度为515°C。这些结果为模拟的逼真度提供了令人满意的置信度