In the present work, the effects of in-process cooling are investigated on the material flow, temperature distribution, axial force, wear resistance, and microstructural and mechanical properties of friction stir processed (FSPed) Al-Si aluminum alloy. The finite element method (FEM) was developed for modeling the process, based on the eulerian-lagrangian technique, and then verified by the experimental force and temperature histories. Next, the material flow and temperature distribution during the friction stir process (FSP) with in-process cooling under different conditions were considered. After that, the experimental investigations, including the optical microscopy, hardness, and wear tests, were conducted. Finally, the stir zone (SZ) shape obtained by experiments and simulation model were compared for the FSPed samples without cooling and with air cooling. The material flow achievements reveal that using a coolant affects the material flow in the pin-driven zone more significantly than in the shoulder-driven zone, leading the SZ to change from the basin shape into the V shape. The SZ shapes obtained from the experiments and the simulation model show a good agreement between the shapes of the samples FSPed without cooling and with air cooling. Moreover, experimental results showed that using in-process cooling reduces Si particles' size and thus significantly increases the hardness and wear resistance. The Si particles size is reduced from 10 μm in the base metal to 2.6 μm and 2 μm in the air-cooled and water-cooled samples. Consequently, the wear mass loss reduced almost 28% and 40%, and hardness increased almost 35% and 80% for the air-cooled and water-cooled samples compared to the processed samples without coolant.

在目前的工作中，研究了过程冷却对搅拌摩擦加工 (FSPed) 铝硅铝合金的材料流动、温度分布、轴向力、耐磨性以及微观结构和机械性能的影响。基于欧拉-拉格朗日技术开发了有限元方法 (FEM) 来模拟该过程，然后通过实验力和温度历史进行验证。接下来，考虑了在不同条件下进行过程中冷却的摩擦搅拌过程 (FSP) 期间的材料流动和温度分布。之后，进行了实验研究，包括光学显微镜、硬度和磨损测试。最后，将通过实验和模拟模型获得的搅拌区 (SZ) 形状与没有冷却和空气冷却的 FSPed 样品进行比较。物料流动结果表明，使用冷却剂对销驱动区的物料流动的影响比肩部驱动区的物料流动更显着，导致 SZ 从盆形变为 V 形。从实验和模拟模型中获得的 SZ 形状表明，FSPed 样品的形状在没有冷却和空气冷却的情况下具有良好的一致性。此外，实验结果表明，使用过程冷却减小了硅颗粒的尺寸，从而显着提高了硬度和耐磨性。Si 颗粒尺寸从贱金属中的 10 μm 减小到风冷和水冷样品中的 2.6 μm 和 2 μm。最后，