The joining of dissimilar materials is required in many engineering and defense applications, and the conventional fusion welding often results in defective welds. The friction stir welding has minimized the welding defects, but not completed. This work focuses on the effect of friction stir processing on TIG-welded joints with filler ER 5356 to improve the mechanical properties of TIG-welded joints. In this paper, the FSP tool pin rotates on an already welded joint by TIG welding to lower the welding load and improve the weld quality by adjusting the processing parameters of friction stir processing. After analyzing the mechanical properties of TIG + FSP-welded joint, computational fluid dynamics-based numerical model was developed to predict the temperature distribution and material flow during TIG + FSP of dissimilar aluminum alloys AA6061 and AA7075 by ANSYS fluent software. The minimum compressive residual stress 18 MPa, maximum tensile strength (281.1 MPa) and hardness (107 HV) were located at the nugget zone of the TIG + FSP weldment at tool rotation speed of 1300 rpm, traverse speed of 30 mm/min and tilt angle 2°. The predicted peak values of temperature at the weld region were calculated and the maximum temperature (505 °C) and maximum heat flux (2.93 × 10⁶ w/m²) were observed at a tool rotation of 1300 rpm.

在许多工程和国防应用中都需要连接异种材料，而传统的熔焊通常会导致焊接缺陷。搅拌摩擦焊已使焊接缺陷最小化，但尚未完成。这项工作着重于搅拌摩擦对填充剂ER 5356的TIG焊接接头的影响，以改善TIG焊接接头的机械性能。在本文中，FSP工具销通过TIG焊接在已经焊接的接头上旋转，以降低焊接负荷并通过调整搅拌摩擦加工的加工参数来提高焊接质量。在分析了TIG + FSP焊接接头的力学性能之后，利用ANSYS fluent软件建立了基于计算流体动力学的数值模型，以预测异种铝合金AA6061和AA7075的TIG + FSP过程中的温度分布和材料流动。在工具转速为1300 rpm，横向速度为30 mm / min且倾斜的情况下，最小压缩残余应力18 MPa，最大抗拉强度（281.1 MPa）和硬度（107 HV）位于TIG + FSP焊件的熔核区。角度2°。计算焊接区域温度的预测峰值，并确定最高温度（505°C）和最大热通量（2.93×10）横移速度为30 mm / min，倾斜角为2°。计算焊接区域温度的预测峰值，并计算出最高温度（505°C）和最大热通量（2.93×10）横移速度为30 mm / min，倾斜角度为2°。计算焊接区域温度的预测峰值，并计算出最高温度（505°C）和最大热通量（2.93×10）⁶ 瓦特/米²）以1300rpm的旋转工具进行观察。