In advanced solid-state manufacturing processes such as friction stir welding, the metal’s temperature ranges from room temperature to the solidus temperature. The material strength in the temperature range is generally required for investigating the mechanical behaviors. In this communication paper, an analytical model is proposed for describing the thermal softening of aluminum alloys for room temperature to solidus temperature, in which the concept of temperature-dependent transition between two thermal softening regimes is implemented. It is demonstrated that the proposed model compares favorably to the well-known Sellars–Tegart model and Johnson–Cook model. The constants of the proposed model for nine typical engineering commercial aluminum alloys are documented.
