Characterization of material flow behavior in friction stir welded AA2014 aluminum alloy joints

Steel rivets serve as a substitute material for connecting similar and dissimilar materials within the structural fabrication industries. However, the use of steel rivets can result in a significant increase in the structure's weight and may trigger corrosion at the interface due to galvanic coupling. Combining dissimilar alloys through the fusion welding process poses numerous challenges for manufacturers and designers. A solid-state welding technique called friction stir welding (FSW) has been developed. FSW can effectively join materials without reaching their melting points, relying on severe plastic deformation and recrystallization to form a welded joint. The proper selection of the tool and process parameters is essential for achieving a sound weld. The findings of this study indicate that plastic deformation, material flow, and recrystallization play pivotal roles in the strength of the joint. This implies that FSW represents an ideal joining process for high-strength alloys and serves as a viable alternative to replace permanent joints like rivets.