Study on Material Flow Behavior in Three-Dimensional Directions During Friction Stir Welding and the Establishment of a Qualitative Model.
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| Title: | Study on Material Flow Behavior in Three-Dimensional Directions During Friction Stir Welding and the Establishment of a Qualitative Model. |
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| Authors: | Wei, Cheng-Gang1 (AUTHOR), Lu, Sheng1,2 (AUTHOR) lusheng_ktz@just.edu.cn, Chen, Jun1,3 (AUTHOR), Zhang, Jun1,2 (AUTHOR), Zhu, Jin-Ling2 (AUTHOR), Gridasov, Alexander V.3 (AUTHOR), Statsenko, Vladimir N.3 (AUTHOR), Pogodaev, Anton V.3 (AUTHOR) |
| Source: | Materials (1996-1944). Apr2026, Vol. 19 Issue 7, p1341. 28p. |
| Subjects: | Friction stir welding, Three-dimensional flow, Magnesium alloys, Welding defects, Welding |
| Abstract: | Highlights: The complex flow behavior of metals around the stirring tool during the welding process has become a core physical process affecting welding quality and process stability. Three methods of marker material configuration were adopted to investigate the three-dimensional material flow behavior during friction stir welding, and a "force-flow coupled simple circulatory flow" model was proposed. The experimental results indicate that three typical characteristic zones exist along the vertical direction, which are the shoulder-affected zone, the pin-affected zone, and the swirl zone from top to bottom. The "force-flow coupled simple circulatory flow" model defines three flow modes corresponding to the different characteristic zones within the weld. This study provides an interpretable qualitative basis for the three-dimensional material flow in friction stir welding. What are the main findings? Three typical characteristic zones exist along the vertical direction, which are the shoulder-affected zone, the pin-affected zone, and the swirl zone from top to bottom. The material in the shoulder-affected zone is dominated by laminar flow; the pin-affected zone exhibits complex mixed-flow characteristics; while the swirl zone shows an obvious rotational flow pattern. A "force-flow coupled simple circulatory flow" model was proposed, which defines three flow modes corresponding to the different characteristic zones within the weld. What are the implications of the main findings? It reveals that there exist substantial differences in the three-dimensional material flow behavior. The formation of welding defects is the result of the superposition of abnormal flows in different material flow zones. The model presents the qualitative relationship between welding process parameters and material flow behavior, and subsequent modeling work will help control welding quality by directly regulating the process parameters. The complex flow behavior of the metal around the stirring tool during welding directly determines the microstructural evolution, defect formation, and mechanical properties of the welded joint, and thus becomes the core physical process affecting welding quality and process stability. In this study, to characterize the three-dimensional material flow behavior of AZ31 magnesium (Mg) alloy during friction stir welding (FSW), conventional metallographic sectioning was adopted as the primary observation method, and copper foil was used as the marker material. The flow trajectories of the materials after welding were investigated via three configurations of the marker material. The results indicate that three typical characteristic zones exist along the vertical direction, which are the shoulder-affected zone (SAZ), the pin-affected zone (PAZ), and the swirl zone from top to bottom. Specifically, the material in the SAZ is dominated by laminar flow; the PAZ exhibits complex mixed-flow characteristics; while the swirl zone shows an obvious rotational flow pattern. Based on the principles of material mechanics and fluid mechanics, a force-flow coupled "simple flow model around a rotating cylinder" was proposed, which defines three flow modes corresponding to the different characteristic zones within the weld. [ABSTRACT FROM AUTHOR] |
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| Database: | Engineering Source |
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| Abstract: | Highlights: The complex flow behavior of metals around the stirring tool during the welding process has become a core physical process affecting welding quality and process stability. Three methods of marker material configuration were adopted to investigate the three-dimensional material flow behavior during friction stir welding, and a "force-flow coupled simple circulatory flow" model was proposed. The experimental results indicate that three typical characteristic zones exist along the vertical direction, which are the shoulder-affected zone, the pin-affected zone, and the swirl zone from top to bottom. The "force-flow coupled simple circulatory flow" model defines three flow modes corresponding to the different characteristic zones within the weld. This study provides an interpretable qualitative basis for the three-dimensional material flow in friction stir welding. What are the main findings? Three typical characteristic zones exist along the vertical direction, which are the shoulder-affected zone, the pin-affected zone, and the swirl zone from top to bottom. The material in the shoulder-affected zone is dominated by laminar flow; the pin-affected zone exhibits complex mixed-flow characteristics; while the swirl zone shows an obvious rotational flow pattern. A "force-flow coupled simple circulatory flow" model was proposed, which defines three flow modes corresponding to the different characteristic zones within the weld. What are the implications of the main findings? It reveals that there exist substantial differences in the three-dimensional material flow behavior. The formation of welding defects is the result of the superposition of abnormal flows in different material flow zones. The model presents the qualitative relationship between welding process parameters and material flow behavior, and subsequent modeling work will help control welding quality by directly regulating the process parameters. The complex flow behavior of the metal around the stirring tool during welding directly determines the microstructural evolution, defect formation, and mechanical properties of the welded joint, and thus becomes the core physical process affecting welding quality and process stability. In this study, to characterize the three-dimensional material flow behavior of AZ31 magnesium (Mg) alloy during friction stir welding (FSW), conventional metallographic sectioning was adopted as the primary observation method, and copper foil was used as the marker material. The flow trajectories of the materials after welding were investigated via three configurations of the marker material. The results indicate that three typical characteristic zones exist along the vertical direction, which are the shoulder-affected zone (SAZ), the pin-affected zone (PAZ), and the swirl zone from top to bottom. Specifically, the material in the SAZ is dominated by laminar flow; the PAZ exhibits complex mixed-flow characteristics; while the swirl zone shows an obvious rotational flow pattern. Based on the principles of material mechanics and fluid mechanics, a force-flow coupled "simple flow model around a rotating cylinder" was proposed, which defines three flow modes corresponding to the different characteristic zones within the weld. [ABSTRACT FROM AUTHOR] |
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| ISSN: | 19961944 |
| DOI: | 10.3390/ma19071341 |
