Material flow and mixing patterns during dissimilar FSW

The main goal of this investigation is to study the flow pattern and mixing which take place during dissimilar friction stir welding (FSW). Aspects such as the origin of onion rings and development of welding defects are considered. An evaluation of the impact of welding parameters (rotational speed) on material mixing of AA 7075-T6 and AA 2024-T3 (3 mm thickness) dissimilar butt welds was performed. The 'stop action' technique has been employed in order to acquire a close snap shot of the flow and mixing in one of the samples which showed limited mixing but optimal mechanical performance and surface condition. A non-stable rotational flow inside the threads has been identified in this sample due to the formation of a cavity on the rear of the pin. This fact gave rise to characteristic bands in the longitudinal section but it was not enough for developing an onion ring-like mixing pattern.