Metallurgical Nature at the Interface between Tool Shoulder and Workpiece during Friction Stir Welding

Knowledge on the contact condition at the tool/workpiece interface is essential for understanding many aspects of FSW. In the present study, FSW experiments were conducted using aluminium alloys followed by metallographic examination focusing on the tool shoulder-workpiece interface region. It was observed that an interfacial intermetallic layer and hence metallurgical sticking/soldering readily formed. Temperature measurements have suggested the presence of interface liquid, hence suggesting a mechanical sliding contact condition dominant. This has been supported by the observation on material flow within the shear layer.