Material Flow Visualization During Friction Stir Welding Using High-Speed X-ray Imaging

This study employs high-speed X-ray imaging to capture the process dynamics during FSW in-situ, using a high-intensity X-ray beam to image a 2 mm x 2 mm area at 20,000 frames per second. The friction stir (FS) tool made of H13 tool steel with threads and 3-flats on the probe was used in an aluminum 6061-T6 workpiece. The process parameters employed result in a fully consolidated weldment without any observable sub-surface voids. The density changes captured by the high-intensity X-ray beam show the formation and filling of cavities in the wake of the tool three times per rotation.(c) 2022 Society of Manufacturing Engineers (SME). Published by Elsevier Ltd. All rights reserved.