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Materials 2013, 6(12), 5870-5877; doi:10.3390/ma6125870
Article

Design of Friction Stir Welding Tool for Avoiding Root Flaws

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Faculty of Aerospace Engineering, Shenyang Aerospace University, Shenyang 110136, China
* Author to whom correspondence should be addressed.
Received: 5 November 2013 / Revised: 18 November 2013 / Accepted: 6 December 2013 / Published: 12 December 2013
(This article belongs to the Special Issue Light Alloys and Their Applications)
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Abstract

In order to improve material flow behavior during friction stir welding and avoid root flaws of weld, a tool with a half-screw pin and a tool with a tapered-flute pin are suggested. The effect of flute geometry in tool pins on material flow velocity is investigated by the software ANSYS FLUENT. Numerical simulation results show that high material flow velocity appears near the rotational tool and material flow velocity rapidly decreases with the increase of distance away from the axis of the tool. Maximum material flow velocity by the tool with the tapered-flute pin appears at the beginning position of flute and the velocity decreases with the increase of flow length in flute. From the view of increasing the flow velocity of material near the bottom of the workpiece or in the middle of workpiece, the tool with the half-screw pin and the tool with the tapered-flute pin are both better than the conventional tool.
Keywords: friction stir welding; material flow; numerical simulation; root flaws friction stir welding; material flow; numerical simulation; root flaws
This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

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MDPI and ACS Style

Ji, S.; Xing, J.; Yue, Y.; Ma, Y.; Zhang, L.; Gao, S. Design of Friction Stir Welding Tool for Avoiding Root Flaws. Materials 2013, 6, 5870-5877.

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