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TEMPERATURE AND PLASTIC STRAIN EVALUATION DURING FRICTION STIR REPAIR OF CORROSION DEFECTS IN Al2024
Authors:
Brahim Lakli1
, Mohamed Berrahou1
, Mohamed Serier2
1Industrial Engineering and Sustainable Development Laboratory – GIDD, Faculty of Science and Technology, University of Relizane, Relizane, Algeria
2Mechanical Engineering Department, University of Ain Temouchent, Ain Temouchent, Algeria
Received: 27 October 2024
Revised: 29 January 2025
Accepted: 24 February 2025
Published: 31 March 2025
Abstract:
This paper presents a novel technique for repairing corrosion in
aluminium plates, leveraging the principles of friction stir technology. The
process employs a rotational speed of 1000 rpm and a traversal speed of
50 mm/min. The method involves applying a filling material to areas
affected by pitting corrosion. A rotating tool generates frictional heat
between the tool shoulder, filling material, and workpiece for a dwell time
of several seconds, ensuring the softening of the material. As the tool
traverses the corroded zone, the material is plastically deformed and
deposited onto the damaged area. Additionally, a finite element
simulation using a coupled Eulerian-Lagrangian approach predicts
temperature distribution and mechanical deformation during the repair
process for AA2024 aluminium plates, with all stages (plunging, dwelling,
and mixing) simulated using ABAQUS/Explicit software. The results
demonstrated that the repair method effectively filled all pitted areas on
the corroded plate, achieving an excellent surface condition. The model
accurately predicted the temperature distribution and the maximum
temperature during the repair process, with the highest temperatures, up
to 453°C (90% of the melting point of aluminium 2024), occurring directly
under the tool shoulder. Additionally, the analysis revealed a maximum
concentration of plastic strain in the same region, highlighting the
localized impact of the repair technique.
Keywords:
Friction stir processing, Corrosion repairing, AA2024, Aluminium alloy, Coupled Eulerian-Lagrangian, Finite element model, Temperature distribution
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© 2025 by the authors. This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
Volume 10
Number 4
December 2025
Last Edition
Volume 10
Number 4
December 2025
How to Cite
B. Lakli, M. Berrahou, M. Serier, Temperature and Plastic Strain Evaluation During Friction Stir Repair of Corrosion Defects in Al2024. Applied Engineering Letters, 10(1), 2025: 25-34.
https://doi.org/10.46793/aeletters.2025.10.1.3
More Citation Formats
Lakli, B., Berrahou, M., & Serier, M. (2025). Temperature and Plastic Strain Evaluation During Friction Stir Repair of Corrosion Defects in Al2024. Applied Engineering Letters, 10(1), 25-34.
https://doi.org/10.46793/aeletters.2025.10.1.3
Lakli, Brahim, et al. “Temperature and Plastic Strain Evaluation During Friction Stir Repair of Corrosion Defects in Al2024.“ Applied Engineering Letters, vol. 10, no. 1, 2025, pp. 25-34.
https://doi.org/10.46793/aeletters.2025.10.1.3
Lakli, Brahim, Mohamed Berrahou, and Mohamed Serier. 2025. “Temperature and Plastic Strain Evaluation During Friction Stir Repair of Corrosion Defects in Al2024.“ Applied Engineering Letters, 10 (1): 25-34.
https://doi.org/10.46793/aeletters.2025.10.1.3
Lakli, B., Berrahou, M. and Serier, M. (2025). Temperature and Plastic Strain Evaluation During Friction Stir Repair of Corrosion Defects in Al2024. Applied Engineering Letters, 10(1), pp. 25-34.
doi: 10.46793/aeletters.2025.10.1.3.