Flow visualization and residual microstructures associated with the friction-stir welding of 2024 aluminum to 6061 aluminum

The friction-stir welding (FSW) of 0.6 cm plates of 2024 Al (140 HV) to 6061 Al (100 HV) is characterized by residual, equiaxed grains within the weld zone having average sizes ranging from 1 to 15 μm, exhibiting grain growth from dynamically recrystallized grains which provide a mechanism for superplastic flow; producing intercalated, lamellar-like flow patterns. These flow patterns are visualized by differential etching of the 2024 Al producing contrast relative to 6061 Al. The flow patterns are observed to be complex spirals and vortex-like, among others, and to change somewhat systematically with tool rotation (stirring) speed between 400 and 1200 rpm; depending on tool orientation. The equiaxed grain and sub-grain microstructures are observed to vary according to estimated temperature profiles (varying from 0.6 to 0.8 TM, where TM is the absolute melting temperature) referenced to the rotating tool axis. Dislocation spirals and loops are also observed in the 2024 Al intercalation regions within the weld zones at higher speeds (>800 rpm) corresponding to slightly elevated temperatures introducing dislocation climb, and residual microhardness profiles follow microstructural variations which result in a 40% reduction in the 6061 Al workpiece microhardness and a 50% reduction in the 2024 Al workpiece microhardness just outside the FSW zone.