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Effect of Alclad Layer on Material Flow and Defect Formation in Friction-Stir-Welded 2024 Aluminum Alloy

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Abstract

The effect of the Alclad layer on material flow and defect formation during friction-stir welding (FSW) of 6.5-mm-thick 2024Al-T351 alloy plates was investigated. To characterize the material flow during FSW, different cross sections of the keyhole and “stop-action weld” were made for metallographic observations. It was found that the top Alclad assembled at the shoulder/workpiece interface, thereby weakening the material flow in the shoulder-driven zone and favoring the formation of void defect at high traveling speeds. The bottom Alclad layer extended into the weld at excess material flow state, which could be avoided at balanced material flow state. A conceptual model of material flow was proposed to describe the formation of the weld. It was indicated that a perfect FSW joint of Alclad 2024Al alloy without defect could be obtained at an optimum FSW condition.

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Acknowledgments

This work was supported by the National Outstanding Young Scientist Foundation of China under Grant 50525103 and the Hundred Talents Program of Chinese Academy of Sciences.

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Authors and Affiliations

  1. Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang, 110016, P.R. China

    Z. Zhang (Postgraduate), B. L. Xiao (Professor), D. Wang (Assistant Professor) & Z. Y. Ma (Professor)

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  1. Z. Zhang
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  2. B. L. Xiao
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  3. D. Wang
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  4. Z. Y. Ma
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Corresponding author

Correspondence to Z. Y. Ma.

Additional information

Manuscript submitted April 27, 2010.

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Zhang, Z., Xiao, B.L., Wang, D. et al. Effect of Alclad Layer on Material Flow and Defect Formation in Friction-Stir-Welded 2024 Aluminum Alloy. Metall Mater Trans A 42, 1717–1726 (2011). https://doi.org/10.1007/s11661-010-0545-3

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