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Material Flow Visualization of Dissimilar Friction Stir Welding Process Using Nano-CT

[+] Author Affiliations
Xun Liu

Ohio State University, Columbus, OH

Sheng Zhao

Shanghai Jiao Tong University, Shanghai, China

Jun Ni

University of Michigan, Ann Arbor, MI

Paper No. MSEC2018-6363, pp. V002T04A035; 8 pages
  • ASME 2018 13th International Manufacturing Science and Engineering Conference
  • Volume 2: Materials; Joint MSEC-NAMRC-Manufacturing USA
  • College Station, Texas, USA, June 18–22, 2018
  • Conference Sponsors: Manufacturing Engineering Division
  • ISBN: 978-0-7918-5136-4
  • Copyright © 2018 by ASME


In this study, Friction stir welding (FSW) of aluminum alloy 6061-T6511 to TRIP 780 steel are analyzed under various process conditions. Two FSW tools with different sizes are used. To understand the underlying joining mechanisms and material flow behavior, nano-CT is applied for a 3D visualization of material distribution in the weld. With insufficient heat input, steel fragments are generally scattered in the weld zone in large pieces. This is observed in a combined condition of big tool, small tool offset and low rotating speed or a small tool with low rotating speed. Higher heat input improves the material flowability and generates a continuous strip of steel. The remaining steel fragments are much finer. When the volume fraction of steel involved in the stirring nugget is small, this steel strip can be in a flat shape near the bottom, which generally corresponds to a better joint quality and the joint would fracture in the base aluminum side. Otherwise, a hook structure is formed and reduces the joint strength. The joint would fail with a combined brittle behavior on the steel hook and a ductile behavior in the surrounding aluminum matrix.

Copyright © 2018 by ASME



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