Influence of pin thread on particle distribution in the FSP using the CEL method

Abstract

Material flow pattern determination during Friction Stir Processing (FSP), while producing a composite substrate is one of the most challenging factors in achieving uniform distribution of reinforcements. This article investigates the effects of pin thread and thread pitch on the distribution of reinforcing particles during the FSP process. It is more challenging when complicated pin designs, including threads, are employed due to the limitations of the numerical model development. To comprehensively evaluate the influence of various tool pin designs on material flow, particle distribution, temperature, and strain, the study employs the Coupled Eulerian-Lagrangian (CEL) modeling technique. Three distinct tool designs with thread pitches of 0.75?mm, 1?mm, and 2?mm were analyzed for their impact on these parameters. The results indicate that samples produced with threaded tools exhibit higher temperatures and strain levels than those processed with circular tools. Moreover, the circular tool design does not facilitate a uniform distribution of particles within the processed zone. Notably, threaded pins with pitches of 0.75?mm and 1?mm effectively promote a more uniform arrangement of particles within the base matrix, enhancing the overall processing outcomes. © 2025 Elsevier B.V., All rights reserved.