Numerical simulation improves ductility in AA2029–SS316L welded joints, highlighting simulation-driven optimization benefits.
Objectives To improve ductility and impact performance of AA2029–SS316L friction stir welded joints by optimizing key FSW process parameters using numerical simulation and statistical analysis. Methods Numerical simulations using ANSYS and Response Surface Methodology were employed, considering beam radius, clearance, force, and HAZ temperature, with ANOVA, fit statistics, and perturbation analysis validating structural responses. Results Optimized parameters – BWC 2.0067 mm, HAZT 1,600.41 °C, and force 5,482.06 kN – significantly enhanced ductility, reduced stress concentrations, and improved joint integrity under impact loading conditions. Conclusions The optimized FSW parameters exceed industry standards, demonstrating improved mechanical performance and structural reliability of AA2029–SS316L joints, confirming the effectiveness of simulation-driven optimization for advanced welding applications.
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Nimal et al. (2026) studied this question.
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