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10.3390/ma19071341
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Article

Study on Material Flow Behavior in Three-Dimensional Directions During Friction Stir Welding and the Establishment of a Qualitative Model

by
Cheng-Gang Wei
1,
Sheng Lu
1,*,
Jun Chen
1,
Jun Zhang
2,
Jin-Ling Zhu
2,
Alexander V. Gridasov
3,
Vladimir N. Statsenko
3 and
Anton V. Pogodaev
3
1
School of Materials Science and Engineering, Jiangsu University of Science and Technology, Zhenjiang 212003, China
2
National Mold Inspection and Testing Center, Kunshan 215300, China
3
School of Engineering, Far Eastern Federal University, Vladivostok 690950, Russia
*
Author to whom correspondence should be addressed.
Materials 2026, 19(7), 1341; https://doi.org/10.3390/ma19071341
Submission received: 27 January 2026 / Revised: 2 March 2026 / Accepted: 24 March 2026 / Published: 27 March 2026
(This article belongs to the Section Materials Simulation and Design)
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Abstract

The complex flow behavior of the metal around the stirring tool during welding directly determines the microstructural evolution, defect formation, and mechanical properties of the welded joint, and thus becomes the core physical process affecting welding quality and process stability. In this study, to characterize the three-dimensional material flow behavior of AZ31 magnesium (Mg) alloy during friction stir welding (FSW), conventional metallographic sectioning was adopted as the primary observation method, and copper foil was used as the marker material. The flow trajectories of the materials after welding were investigated via three configurations of the marker material. The results indicate that three typical characteristic zones exist along the vertical direction, which are the shoulder-affected zone (SAZ), the pin-affected zone (PAZ), and the swirl zone from top to bottom. Specifically, the material in the SAZ is dominated by laminar flow; the PAZ exhibits complex mixed-flow characteristics; while the swirl zone shows an obvious rotational flow pattern. Based on the principles of material mechanics and fluid mechanics, a force-flow coupled “simple flow model around a rotating cylinder” was proposed, which defines three flow modes corresponding to the different characteristic zones within the weld.
Keywords: friction stir welding; material flow; marker material; force-flow coupling model; flow with circulation friction stir welding; material flow; marker material; force-flow coupling model; flow with circulation

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MDPI and ACS Style

Wei, C.-G.; Lu, S.; Chen, J.; Zhang, J.; Zhu, J.-L.; Gridasov, A.V.; Statsenko, V.N.; Pogodaev, A.V. Study on Material Flow Behavior in Three-Dimensional Directions During Friction Stir Welding and the Establishment of a Qualitative Model. Materials 2026, 19, 1341. https://doi.org/10.3390/ma19071341

AMA Style

Wei C-G, Lu S, Chen J, Zhang J, Zhu J-L, Gridasov AV, Statsenko VN, Pogodaev AV. Study on Material Flow Behavior in Three-Dimensional Directions During Friction Stir Welding and the Establishment of a Qualitative Model. Materials. 2026; 19(7):1341. https://doi.org/10.3390/ma19071341

Chicago/Turabian Style

Wei, Cheng-Gang, Sheng Lu, Jun Chen, Jun Zhang, Jin-Ling Zhu, Alexander V. Gridasov, Vladimir N. Statsenko, and Anton V. Pogodaev. 2026. "Study on Material Flow Behavior in Three-Dimensional Directions During Friction Stir Welding and the Establishment of a Qualitative Model" Materials 19, no. 7: 1341. https://doi.org/10.3390/ma19071341

APA Style

Wei, C.-G., Lu, S., Chen, J., Zhang, J., Zhu, J.-L., Gridasov, A. V., Statsenko, V. N., & Pogodaev, A. V. (2026). Study on Material Flow Behavior in Three-Dimensional Directions During Friction Stir Welding and the Establishment of a Qualitative Model. Materials, 19(7), 1341. https://doi.org/10.3390/ma19071341

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