TWI

An experimental investigation was made of the effect of welding tool shape on welding defects and material flow during friction stir welding (FSW) of dissimilar materials. Friction stir welding tools used had tool shoulders of tool steel and the probes of WC-Co cemented carbide and the probes were either straight or screws. Weld defects were evaluated with cross-section macrostructures of FSW joints of aluminium AA6061 and steel S45C (6 mm thickness). The material flow between the two materials was investigated by way of a simulation experiment using 20 mm thickness transparent PVC and S45C. Particle image velocimetry (PIV) and high speed video camera were used to measure material flow from the weld interface. The internal temperature of the weld and the three-dimensional force during welding were also measured.

8th International Symposium, 18-20 May 2010, Session 5B: Modelling 2, Paper 03