: ..

2010

4
.5
ABSTRACT.6
1 : 7
1.1 ...7
1.2 .8
1.2.1 (G.T.A.W)8
1.2.2 (G.M.A.W)..10
1.2.3 (P.A.W)12
1.2.4 (E.B.W)...14
1.2.5 (L.B.W)..15
1.3 (F.S.W)16
2 : ..17
2.1 ...17
2.2 .18
2.3 F.S.W..19
2.4 ..20
2.5 ..21
2.6 23
2.7 .24
2.8 .24
2.9 .25
3 : 27
3.1 .27
3.2 .....27
3.3 ..28
3.4 .29
3.4.1 ..31
3.4.2 .38
4 :
( ).41
5 : .48
5.1 ...48
5.1.1 .48
2

5.1.2 .50
5.1.3 .50
5.1.4 .51
5.1.5 .52
5.1.6 ..52
5.1.7 ...53
5.2 ...54
5.3 .54
6 : ..59
6.1 ..59
6.1.1 ..59
6.1.2 ..61
6.2 FSW..62
6.3 .90
6.3.1 ..90
6.3.2 ..92
6.3.3
95
7 : .99
8 : FSW...104
9 : 113
10 : ...115



.

,
.
.
,
, .
, ,
,

. ,
,

. ,

, .


(F.S.W),
,
. ,

0,8
. F.S.W
.
,
,
. ,
(, Marker Insert
Technique). AA5083 111 6
mm, .

. ,
. ,

.

ABSTRACT
Friction stir welding (FSW), as a solid state joining process, is considered to be
one of the most advanced methods of welding of the last decade. During this process,
plastic deformation of welded material takes place and the values of temperature can
reach above 0.8 of the melting point of the material to be welded. One of the most
important aspect of FSW is the observation of material flow during this process.
Within the scope of this study, in order to observe material flow during FSW,
joining is applied using different parameters of the process. Material flow is observed
using Marker Insert Technique (MIT). For this reason, workpieces of AA5083 H111
with thickness of 6 mm were used and wires of copper were inserted in specific holes
which were created in the workpieces. Afterwards, microstucture and microhardness
of a reference workpiece were observed as well as material flow using optical
stereoscopy and microscopy. Then, the results were combined to produce a physical
model. Finally, a theoretical approach of material flow during FSW is proposed and
the results of this approach are compared with experimental values.

 1 :
1.1 [1]
.
,
.

,
, , .. ,
,
.

1881 :
, Moissan ()
1885 :
, Bernardos ()
1892 : , Slavianoff ()
1895 : , Le Chatellier ()
1907 : , Kjellberg ()
1930 : - (..)
- , Hobart
Dever (..)
1946 : , , GMAW
(..)
1950 : electroslag ()
1955 : (..)

1.2 [1]
,
:

(G.T.A.W)

(G.M.A.W)

(P.A.W)

(E.B.W)

(L.B.W)

(F.S.W)

1.2.1
(G.T.A.W) [1]

.
.
.

1. ( 40) :
-

1,33
2. ( 4) :

..

:
1.

2. 1 2 %
3. 0.15 0.40 %
4.
1 2 %

0.25 6.35 mm 76 610 mm.

G.T.A.W .
G.T.A.W
( )
. ,

,
.

1.1 : G.T.A.W. [1]

1.2.2
(G.M.A.W) [1]
GMAW


.

,
.
. ,

( CO2).

:
1.
a. ( 25 mm)
b. 75% He + 25% Ar 25 76 mm
c. 90% He + 10% Ar
2.
a. Ar + 5% 2
b. Ar + 25% C2 3.2
mm, Ar + 50% C2 , C2

3.
a. 1 2 % 2
b. 90% He + 7.5% Ar + 2.5% C2

10


, ,

. ,
.

1.02 1.59 mm, ( 0.5 mm)
( 3.18 mm) .

G.M.A.W
.
.

G.M.A.W,

.
G.M.A.W
.
: ,
,
, , .

1.2 : G..A.W. [1]

11

1.2.3 (P.A.W) [2]

.

( )
.
,
.
( ). ,
.

G.T.A.W,
. ,
.A.W
.

: ,
. ,
.
,
.

. , ,

.


, ,
.
,
.

12


,
keyhole
, .
keyhole
.

,
.
,

,
. ,
20 50%
.

.

. ,
,
,
.

1.3 : P.A.W. [2]

13

1.2.4 (E.B.W) [3]

. ,

.
E.B.W

< 100 kW

: 1:3

: 12 m/min

servo

: 150 mm

1.4 : E.B.W. [3]

14

1.2.5 (L.B.W) [4]

.
.

L.B.W

25 mm

: Al, Ti, St, Cu,

2.5-8 m/min

15

1.3 (F.S.W) [2]

, , (1991)
(The Welding Institute T.W.I).
,
0,8
.
2.

1.5 : F.S.W. [5]

16

 2 :
2.1 [6]
(Friction Stir Welding,
F.S.W), (The Welding
Institute, TWI), 1991,
. ,

. F.S.W.
.

2.1 : . [6]

17

2.2 [2]
:
, ,
,
.
,

.

,
.

: ) )
.

, .

,
.

.
,
,
.
F.S.W.
, ,
..

18

 2.2 : . [7]

2.3 F.S.W. [7]

, ( )
:
( )
F.S.W. .
,
.

.

,
.
,
.


,
. FSW
19

 .
:
1.
2.


.
.

.
.
.

2.3 : F.S.W. . [8]

2.4 [9]
:

90.

,
.

, .

20

,
.

2.4 : F.S.W.
. [9]

2.5 [7]

:
(stir zone or weld nugget),
(Thermomechanical Affected Zone, TMAZ) (Heat
Affected Zone, HAZ).

21

 (stir zone)

,
.
FSW
.
, , ,

,
.
(Thermomechanical Affected Zone)
,
().
.
,
.
(Heat Affected Zone)
().

.
, FSW
.

2.5 : FSW.
,
. [8]

22

2.6 [10]
,
FSW. ,

,
.
, ,
,
.
.
, , ,
. ,

.

2.6: ,
.
. [10]

23

2.7 [7]

.
,
.

. ,

.
FSW
.
2.8 [7]
F.S.W.
.
.

, :

, , .

, :

,
.

,
...

24

. ,
,
,
.
, ,
,
.
2.9 [2]

F.S.W. .
, ,
.
F.S.W. ,

.
:

2000 (Al-Cu)

5000 (Al-Mg)

6000 (Al-Mg-Si)

7000 (Al-Zn)

8000 (Al-Li)

F.S.W.
.
:

25

( 50mm )

C-Mn

(, , duplex)

, , .

2.7 : FSW. [2]

26

 3 : [11]
3.1
.
,

.
(/)
(TS/), . ,
.

3.2
.
26,9815, ,
660C (1.220F), 2.467C (4.473F),
2,7(kg/m3 g/cm3).
.
,
Al2O3
.
, , .
, . ,
.
, ,
, .

27

 . ,
99,996% 49 MPa,
700MPa .

3.3
, 1/3
.
,
(
), , ,
, ,
(.. ,
...).
,
, ,
.
63% ,
. ,
,

(
700,000V ).
,
( )

.

28

3.4
,
,
. ,

.

.

.
,
.
,
,
. , ,
, , .

1XXX 99%
2XXX
3XXX
4XXX
5XXX
6XXX
7XXX
8XXX
9XXX
3.1:
Aluminum Association, .

29


1XXX 99%
2XXX
3XXX
4XXX
5XXX
6XXX
7XXX
8XXX
9XXX
3.2:
Aluminum Association, .

, , ,
. 3.3.

F
O
H
H1X

H2X

H3X

,
, (
)
H11:
H12: 25%
H14: 50%
H16: 75%
H18: 100%
H19:
.
1 8,


,
. 1
8,
.

T1:

T2: ,

T3: , ,

T4: ,

30

T5:
,

T6: ,

T7: ,

T8: , ,

T9: , ,

T10: ,

.

3.3: Aluminum
Association, .

3.4.1

1000, 3000 5000. ,

.
,
, .

1000

99% Al.
, .

.
.
, 1% (
1100).
, ..

31

3000

.
Mn Al, 1,8% 659 C,
.
Mn Al, Al6Mn.
Al Mn, 1,5%,
. ,
Al6Mn
. , 0,12%,
. Mg, 1,2%,
, .
Al-Mn ,
. 1000,
.

3.1: - . x-
.

5000

, ,
4%. Mg
Mg2Al3
.
5000, ,
, , .
,

32

 .
,
.

5083, .
5083
5083 .
. ,

.
5083 :

Si

0.4

Fe

0.4

Cu

0.1

Mn

0.4-1.0

Mg

4.0-4.9

Zn

0.25

Ti

0.15

Cr

0.05-0.25

Al

Balance

3.4 : 5083.

33

 5083 :
Temper

32

0/111

Proof Stress 0.2% (MPa)

240

145

Tensile Strength (MPa)

330

300

Shear Strength (MPa)

185

175

Elongation A5 (%)

17

23

Hardness Vickers (HV)

95

75

3.5 : 5083

5083 :
Property

Value

Density

2.65 g/cm3

Melting Point

570C

Modulus of Elasticity

72 GPa

Electrical Resistivity

0.058x10-6 .m

Thermal Conductivity

121 W/m.K

Thermal Expansion

25x10-6 /K

3.6 : 5083

5083 :
5083 :

34

2000, 6000 7000.

2000

Al-Cu, 2,6 6,3%

Al Cu Mg, 0,5 1,5%.
CuAl2
CuMgAl2, .
Si Mn, 0,8%,

.
Fe ,
Cu2FeAl7, ,
. ,
Ni, Al9FeNi,
, 230 C.
2000, ,
,
,
, ,
.

,
,
. ,

(.. ).

35

 3.2 : ,
. r
, t .

6000

Al Mg Si.
Mg2Si, ,
Mg Si, (Mg/Si) 1,73. Si
,
.
, Mn,
0,8%, Cr, 0,3%. ,
,
.
, , ,
0,5%,
.
6000
,
, 150C. ,

.

36

 3.3 : Mg Si .

7000

Al Zn Mg Al Zn Mg Cu. ,
,
.
Zn 4 8% Mg 1 3%.

MgZn2. , 2%,
. ,
, ,
Al Mg Zn. , 0,3%
,
Zn .
7000 ,
,
, ,
,
160C. ,
7000 . ,
.
, ,
( 120C).

37

 7000 , ,

,
.

3.4.2

.
.

:
9
9
9
9
9
9
,

:

:
.

.
,

38

.
, .
:

2.

-

.

3.

-, - --.
5 20%,
.
. 0.3 1%
3-5%
-. --,
(12.7% Si),

.

5.

-.
-
. , .

7.

- -. ,

39

. , ,

. ,
.

40

 4 :
( )

, , .

4.1 :
FSW. , . [10]

.
, .
,


, . ,
. [12]
, ,

. ,
. [13]

. ,
.

, .

41

, FSW
( )
.

.
.
. ,

.
. [14]

4.2 : . [14]

42



FSW Colligan [15],
Al6061 Al7075. ,

.
,
. ,
.
Colligan [15] :

.

, .
Reynolds [16]
.
Al5454,
Al2195. ,

.
, M.Guerra [10]
, 6061
,
.
,
.
:
.


.

.
43

 Ying Li [13]
Al2024 Al 6061.

Kellers
.

.
, ,
.
, J.Schneider [17]
,

FSW .
Rudolf Zettler [18]
.
l2024 351 4 mm.
Ti,
1,25 mm, 10 mm 2,5 mm
.
.
.

i,

. ,

,
.
,
, .
,
FSW.
O Zhao, Lin [14]
,
. ,
44

,
,
. ,

.


.
FSW .

4.3 :

4.3 : (a) , (b) ,

(c) . [14]

. ,

. ,
( ) ,
. [14]

45



FSW.
Xu [19],
FSW.
Zhang

Chen [20],

. ,

.

. ,

.
.
,
.
O Colegrove Shercliff [21]
FSW CFD
.
. ,
. ,

.
Smith Bendzsak [22]
.
, ,

.
: )
, )
)
, .

46

 Arbegast [23]
FSW.
,
.
, ,
, ,
, ,
.

[24].
.


.
. ,
.

47

 5 :
5.1
5.1.1

( 5.1)
FSW
.
x, y
z. ,
90, FSW.

5.1 : .

48

 5.2.
. ,
,
,
.
30
rpm 1500 rpm 19 mm/min 950
mm/min.
.

5.2:
.

(: 3,8mm) 5,2mm
(: 22,9 mm).
(: 3,4mm) 0,1 mm 4,4 mm
22,4 mm.

2mm

()

()

5.3: :
() () .

49

5.1.2

.
Struers Discotom 50 ( 5.4).

5.4 : Struers Discotom 50.

5.1.3


. LaboPol-5
Struers ( 5.5).
50 500 .
.
:
SiC .
220, 500, 1000, 1200, 2400 4000 grit.

.

50

 5.5 : - (Struers LaboPol-5)

.

,
. ,
. ,
, .
1m 0.1m.
,

( )

5.1.4

.

Poultons. 4
, :

20 ml Poultons (12 ml HCl, 6 ml HNO3, 1 ml HF 1ml H2O)

10 ml HNO3

16 ml 3g Cr2O3/10ml H2O (12ml H2O+4g Cr2O3)

51

5.1.5

LEICA MZ6,
.
(0,63x, 0,80x, 1,00x, 1,25x, 1,6x, 2,0x, 2,5x, 3,2x, 4,0x).
,
. ,

(Image Pro Plus Image Analysis).

5.6 :

.

5.1.6

LEICA DM ILM ( 5.7)
.
.
10x, 20x, 50x 100x

52

10x. , ,
(x,y, -)
8kg 35W.

5.7 :

.

5.1.7

Wolpert Wilson Instruments Model 402MVD

.
Vickers.
, ,
136.
Vickers, 5 1000 Vickers,
2

kg/mm :

VPN =

F
136o
F
2sin
= 1,854 2
2
d
2
d

F (5 120 kg) 15 sec

d .

53

5.2
5083 H111
6mm
. ,
, ,
. 5083-111
:
5083 :

Si

0.4

Fe

0.4

Cu

0.1

Mn

0.4-1.0

Mg

4.0-4.9

Zn

0.25

Ti

0.15

Cr

0.05-0.25

Al

Balance

5.1 : 5083.

5.3
(. 5.2)
(FSW).
,
FSW, 1,7 mm ,
. , R,

.
5083-111
6mm 2mm
, ,

54

 5.8 5.9. 5.2

.
5.2 : .

R
1
2
3
4
5

(mm/min)
(RPM)
Cu
Cu
Cu
Cu
WC

85
75
85
85
85
85

600
475
475
600
600
475

conical
conical
conical
conical
screw
conical

2
2

(5),
( 5.8). 3 4 ,
, 5.9.

150 mm

6mm

6mm

55 mm

1
2mm
35 mm

1,7 mm

100 mm

2mm

2
2mm

5.8 : .

55

6mm

2mm

40 mm

1,7 mm

150 mm

55 mm

41,5 mm

3
4

180 mm

5.9 :
.

5.10
, 5.11, 5.12 5.13,
:

A D V A N C IN G
S ID E

R E T R E A T IN G
S ID E

5
4 ,2
W E L D IN G
D IR E C T IO N

4 ,1
3 ,2

TOOL
R O T A T IO N

3 ,1
2 ,2

2 ,1
1

5.10 : .

56

, 1,
5.11 :
A D V A N C IN G
S ID E

R E T R E A T IN G
S ID E

14 mm

3 ,2

14 mm

3 ,1
2 ,2

2 ,1
5.11 : 1 .

2 ( 5.12) :

A D V A N C IN G
S ID E

R E T R E A T IN G
S ID E

14 mm

3 ,2

14 mm

3 ,1
2 ,2

14 mm

2 ,1
1

5.12 : 2 .

57

 3 4 ( 5.13) :

R E T R E A T IN G
S ID E

17 mm

A D V A N C IN G
S ID E

8 mm

5
4 ,2

8 mm

4 ,1
3 ,2

8 mm

3 ,1
2 ,2

17 mm

2 ,1
1

5.13 : 3 4 .

58

 6 :
6.1
,
FSW R,
, ,
, 5.2.
6.1.1
( 6.1.1.1) ,
, ,
.
.
,

.
,
(),
.
, ,
. ()
.
, .
,
.
.

6.1.1.1 : FSW 5083.

59

 6.1.1.2(),
(AA5083),
.
( 6.1.1.2()),
: () ,
() () .
( 6.1.1.2()),
.
.

()

()

()
6.1.1.2 : FSW 5083: () , () ,
, () .

.
,
, ,
.

60

6.1.2

R ,
1,5 mm .

( 6.1.2.1). x-

y-

HV0.3.
70-89 HV .

. AS.
(90-95 HV0.3).

6.1.2.1: HV0.3 , AS
RS .

61

6.2 FSW
FSW
,
.


.
75 mm/min 475 RPM.
,
:
2,1
2,1 ( 6.2.1)
,
. ( 6.2.2,
6.2.3), ,
, (retreating
side).
,
6.2.2.

L1=5,3 mm

(A S)

2,1mm

4,5mm

(R S)

L2=3,1 mm

6.2.1 : 2,1.

62

 6.2.2 : 2,1
.

6.2.3 : 2,1
.

2,2
2,2 ( 6.2.4)
,
( 6.2.4,6.2.6)
. ,
.

6.2.5,
() .

5,1 mm

RS

2 mm

4,9 mm

AS

3,2 mm

6.2.4 : 2,2.

63

 6.2.5 : 2,2,


.

6.2.6 : 2,2,
.

3,1
2,2 3,1
( 6.2.7),
. ,

( 6.2.8). ,

.

5 mm

AS

1,8 mm

5,3mm

3,2 mm

6.2.7 : 3,1.

64

RS

 6.2.8 : 3,1,

.

6.2.9 : 3,1, FSW.

3,2
3,2 ( 6.2.10)
(
6.2.12). , 6.2.11
FSW.

RS

AS

3,2 mm
1,5 mm

5,4 mm

1,8 mm

6.2.10 : 3,2

65

 6.2.11 : 3,2,

FSW.

6.2.12 : 3,2,
.

FSW. .
, ( 6.2.1)

. ,
( 6.2.7).
, ,

, ,
.
,

, ,
. ( 6.2.5, 6.2.8 6.2.12).
,
Guerra[10] Ying Li[13]
, .
Colligan[15], 2,1,

.
( 6.2.1, 6.2.4 6.2.7)

. ,
66


5 5,3 mm,
3,1 3,2 mm.
1,8 2,1 mm.


, 85 mm/min
475 RPM.
:
1
1 ( 6.2.13)

. ,
( ).
1 ( 6.2.14 6.2.15),
, .
, 6.2.13 6.2.14
,
.

3,9 mm

RS

AS
1,4 mm

5,3 mm
1,6 mm

6.2.13 : 1.

67

 6.2.14 : 1,
.

6.2.15 : 1
.

2,1
2,1 ( 6.2.16) ,
.
,
, ,
. 6.2.17 6.2.18

. , -
.

5,22 mm

AS

RS
3,48 mm

5,21 mm

1,3 mm

6.2.16 : 2,1.

68

 6.2.17 : 2,1, ,
.

6.2.18 : 2,1,
.

2,2
2,2 ( 6.2.19) ,
.
, ,
,
.

, .
,
( 6.2.20).
5,24 mm

4,35 mm

5,22 mm

RS

AS

1,5 mm

6.2.19 : 2,2.

69

 6.2.20 : 2,2,
.

6.2.21: 2,2 .

3,1
3,1
( 6.2.22)
. ,
. ,

.
. 6.2.23
6.2.24,
.

AS

RS

6.2.22 : 3,1.

70

 6.2.23 : 3,1,
.

6.2.24 : 3,1, ,
FSW.

3,2
3,2 ( 6.2.25, 6.2.26 6.2.27) ,
,
, ,
( 6.2.26).
.

5,65 mm

4,13 mm

5,22 mm

RS

AS
3 mm

6.2.25 : 3,2.

71

 6.2.26 : 3,2, .

6.2.27 : 3,2, .

,
,
, :
( 1), ( 2,1 2,2) ( 3,1
3,2). :

( 6.2.13),
,
. , ,
, . ,

.

( 6.2.16 6.2.19),

.

().

, ( 6.2.22 6.2.25),
. ,

.

72

 3
,
.
,
. ,
.
.
, ,

.

Guerra [10] Ying Li [13],
, ,
. ,
Smith Bendzsak [22],
.


2 . 85 mm/min
600 RPM.
:
1
1 ( 6.2.28)
.
,
( 6.2.29).
( 6.2.29) ( 6.2.31).

,
( 6.2.28).

73

5,36 mm

3,21 mm

4,29 mm

RS

AS
1,43 mm

6.2.28 : 1.

6.2.29 : 1,

.

6.2.30 : 1,
.

6.2.31 : 1,
.

74

 2,1
2,1 ( 6.2.32),
, .

( : 4,29 mm).

() ,
. ( 6.2.33 6.2.34)
.

4,29 mm

1,85 mm

AS

4,64 mm

RS

2,14 mm

6.2.32 : 2,1.

6.2.33 : 2,1,
.

6.2.34 : 2,1,
.

75

 2,2 3,2
2,2 3,2 ( 6.2.35, 6.2.38 6.2.41)
,
,
, .
.
( 6.2.36 6.2.43).

4,7 mm

2,5 mm

4,29 mm

RS

AS
2,32 mm

6.2.35 : 2,2.

6.2.36 : 2,2,

.

6.2.37 : 2,2,
.

76

5,7 mm

2,85 mm

4,64 mm

AS

RS
2,5 mm

6.2.38 : 3,1.

6.2.39 : 3,1,

.

6.2.40 : 3,1,
.

5,71 mm

3,21 mm

RS

4,35 mm

2,86 mm

6.2.41 : 3,2.

77

AS

 6.2.42 : 3,2,
.

6.2.43 : 3,2,
.

4,1 - 5
4,1 5 ( 6.2.44, 6.2.47 6.2.50)
. , ,
,
( 6.2.47 6.2.50).
6.2.48, 6.2.49, 6.2.51 6.2.52,

. ,
.

5,15 mm

2,89 mm

4,64 mm

AS

RS
2,51 mm

6.2.44 : 4,1.

78

 6.2.45 : 4,1,
.

6.2.46 : 4,1,
.

3,21 mm
1,25 mm

2,68 mm

RS

AS
1,51 mm

6.2.47 : 4,2.

6.2.48 : 4,2,
6.2.49 : 4,2,
. .

79

5,35 mm

3,11 mm

AS

4,64 mm

2,52 mm

RS

6.2.50 : 5.

6.2.51 : 5,

.

6.2.52 : 5,
.

3 . , 1
( 6.2.28) 2,1 ( 6.2.32), ,
, .
,

.
.
, ( 2,2 ( 6.2.35)
3,1 ( 6.2.38)), ( 3,2
( 6.2.41) 5 ( 6.2.50)),
. ,
80

 ,
. Colligan
[15]. ,
,
Zhao, Li [14].


2 . 85 mm/min
600 RPM.
.
:
1
1 ( 6.2.53)
.

. ,
( 6.2.54 6.2.55). 6.2.54
.


.

6.2.53 : 1.

81

 6.2.54 : 1, .

6.2.55 : 1, .

2,1 3,1
2,1 3,1 ( 6.2.56, 6.2.59 6.2.63)
.

.
,
( 6.2.58, 6.2.61, 6.2.62 6.2.64).
, 6.2.62.

6.2.56 : 2,1.

82

 6.2.57 : 2,1, .

6.2.58 : 2,1, .

6.2.59 : 2,2.

6.2.60 : 2,2,
.

6.2.61 : 2,2,
.

83

 6.2.62 : 2,2,
.

6.2.63 : 3,1.

6.2.64 : 3,1 - 6.2.65 : 3,1 .

.

84

 3,2 4,1
3,2 4,1 ( 6.2.66 6.2.69)

.
. , 6.2.68
6.2.71 ( ).

6.2.66 : 3,2.

6.2.67 : 3,2,
.

6.2.68 : 3,2,
.

85

6.2.69 : 4,1.

6.2.70 : 4,1,
.

6.2.71 : 4,1,
.

4,2 - 5
4,2 5 ,
4,2 ( 6.2.72)
, 5 ( 6.2.75)
.

86

6.2.72 : 4,2.

6.2.73 : 4,2,
.

6.2.74 : 4,2 ,
.

6.2.75 : 5.

87

 6.2.76 : 5,
.

6.2.77 : 5 .

,
.
, ,

. ,
.
, Zhao, Lin
[14],
. , ,
, ,
, ,
. , , ,
,
Colligan [15] .

88



2 mm,
FSW,
(<65m)
6.2.88 6.2.91.
:

: 85 mm/min

: 475 RPM

6.2.88 : 1,
.

6.2.89 : 2.1,
.

6.2.90 : 1,

.

6.2.91 : 2.1,
.

89

6.3
6.3.1
,
.
:

: 475 RPM

: 75 mm/min 85 mm/min

2,1
6.3.1.78
. , ()

, . (),
.


.

()
()
6.3.1.78 : () 75mm/min ()
85mm/min.

90

 2,2
6.3.1.79 ()
,
. ,
. ()

.
()
.

.

()
()
6.3.1.79 : () 75mm/min ()
85mm/min.

FSW.
75 mm/min,
, ,
.
, ,


91

 . ,
85 mm/min . ,
.
,
. ,

.
6.3.2

.
:

: 600 RPM

: 85 mm/min

: 2

1
6.3.2.80
. ()

. () .
, ( - )

.
.

92

()
()
6.3.2.80 : () () .

2,1
6.3.2.81 ()

, .
,
()
. ,
.

()
()
6.2.81 : () () .

93

 2,2 5
6.3.2.82 6.3.2.83 ()

() . ()
,

. () ,
, . ,
.

()
()
6.3.2.82 : () () .

()
()
6.3.2.83 : () () .

94

 6.3.2.80 6.3.2.83

.
. ,

,
.
, ,
.
,

.
. , () ,
,
. , ()
.
6.3.3

,

. ,
. ,
.
:

: 85 mm/min

:
2

: 475 RPM 600 RPM

95

 1
6.3.3.84
.
, ()
.
,
. ()
,
.

()
()
6.3.3.84 : () 475
RPM () 2 600 RPM .

2,1
6.3.3.85 ()
.
, , ( ),
. ()

, .

96

()
()
6.3,3.85 : () 475
RPM () 2 600 RPM .

2,2
() () 6.3.3.86
.

. ()
, () .
()
, .
()
.

()
()
6.2.86 : () 475
RPM () 2 600 RPM.

97

 3,2
() 6.3.3.87
.
,
.
. (),
.


.

()
()
6.3.3.87 : () 475
RPM () 2 600 RPM.

,
FSW. (
475 RPM)
. ,
,
. ,
( 2 600 RPM),
.
, ,
.

98

 7 :

,
.
, 1 2
(.
7.1).
7.1: 1 2 .

1 (75mm/min)

2 (85mm/min)

t0=0sec

t0=0sec

0
x0=0mm

1
x1=16mm

t1=12,80sec

t1=11,29sec

2
x2=30mm

t2=24,00sec

t2=21,19sec

3
x3=32mm

t3=25,60sec

t3=22,59sec

99

4
x4=46mm

t4=36,80sec

t4=32,48sec

,
FSW. 75 mm/min,
,
. ,

. ,

,
. ,
85 mm/min . ,

.
. ,
,
.
. ,
,
,

100

, 3 4 (.
7.2),
.
7.2 : 3 4 .

3 ( )

4(
)

0
x0=0mm
t1=0sec

1
x1=17mm
t1=12,00sec

2
x2=19mm
t2=13,42sec

3
x3=27mm
t3=19,06sec

101

4
x4=29mm
t4=20,48sec

5
x5=37mm
t5=26,13sec

6
x6=39mm
t1=27,54sec

7
x7=47mm
t7=33,19sec

8
x8=49mm
t8=34,60sec

. ,
102

 , .
,
. ,

. ,

,
.
,
. ,
, . ,
.

103

 8 : FSW

,
.
Carter Hamilton, Stanislaw Dymek Marek Blicharski [25],
,
.
()
()
(extruded material)
.
(surface material),
,
FSW. ,
FSW,
.

Carter Hamilton , 2 Al 6061-6
6,35 mm 195 mm,
0,05 mm .

90, 8.1.
21 mm. 900 RPM
5 mm/sec.
,

. , 190 x
150 mm 6 mm,
FSW .
1,7 mm .

104

 22,4 mm. 85 mm/min

600 RPM. , 2 .

8.1 : Carter Hamilton. [25]

,
,
, 8.2.

8.2 :
FSW. [25]

.
,
. ,
,

, 8.3. ,

105


.
, ,
.

8.3 : .[25]

Heurtier [25] 3 FSW :

(circumventing)

(torsional)

(vortex)

,
.
, ,
, ,

.

:

ucir = U w [1- R 2

cos 2
],(1)
r2

Uw , R , r

(. 8.4).
:

utor = rU tor

106

z
sin , (2)
t

 Utor , z
t
.

8.4 : .[26]

re, ucir = utor :

U w [1- R 2

cos 2
z
] = rU tor sin ,
2
r
t

z = t = -90 :
Uw
R2
[1 + 2 ], (3)
U tor
re

re =

Utor

, , re (scaling factor )
:

U tor = re , (4)

:

Uw
R2
= 2 [1 + 2 ], (5)
re
re


( 5.2).

107

 _ : U w = 85mm / min U w = 1, 416mm / sec

_ : = 2

600
= 62,83rad / sec
60

_ : R = 11, 2mm
_ _ _ _ : re = 3,5mm

(1)
:

ucir = U w [1- R 2

cos 2
]
r2

ucir = 1, 416[1-11, 22

cos 2(-90)
]
3,52

ucir = 15,92mm / sec

,
(5) :

Uw
R2
[1
+
]
r 2
r2

1, 416
11, 22
[1
+
]
62,83(3,52 )
3,52

= 0, 02

, (2) :

108

z
sin
t
_ _ _ :

utor = rU tor
r = re
z =t

= 90o
U tor = re = 0, 02 62,83 3,5radmm / sec
U tor = 4,39radmm / sec
_ _ _ _ : utor = 15,36rad / sec

,
.
,
, d, 8.5.
:

d=

2 U w

, (6)

( 8.5)

:

Adie =

2 U w

w, (7)

w .

8.5 :
.

109

 , ,
t.


re.
:

Vring = 2 re wt , (8)


(7) (8) :

2 re wt = Adiel
, :

l=

rt

Uw

l=

3,5 0,1 62,83

1, 416

l = 15,53mm / tool _ revolution

10
:
l = 155,3 mm
,

, 1 ( 8.6).
= 9,72 mm2. 26%
, Cu = 2,53 mm2. Cu
( t = 0,016 mm ) l = 157,95 mm
.
, ,
1,67 %,
,

.
110

 8.6 : 1 4.

Carter Hamilton [25],

, ,
189 mm.

175 mm, 8 %.
Hamilton [25] ,
. ,
Hamilton [25]
( 8.7),
.

8.7 :
.
, (dark field image). [25]

, Hamilton [25],
8.7 .

111

112

 9 :

, Al 5083 1111 6 mm ,
:
FSW,
: , .
, 75 mm/min
475 RPM, ,
. .
,
.
, 75 85 mm/min,
.
. ,
,

.
, 600
RPM 2 . ,
, ,
FSW, . ,
, ,
.
,
.
, ,

. ,
,
.
, ,

113


.
,

l =155,3 mm,
1,67 % .

114

 10 :
1. ., .,
, , .., 1994.
2. The Welding Institute- www.twi.co.uk
3. www.weldingengineer.com
4. www.praxair.com
5. www.loxin2002.com
6. Department of Materials Science& etallurgy, University of Cambrigde
www.msm.cam.ac.uk
7. R.S. Mishra, Z.Y. Ma, Friction stir welding and processing, Materials
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patterns during friction stir welding, Materials Characterization, vol. 49, no.
2, pp 95-101, 2002.

11. .. , .. ,
, . , 2007.

115

12. Material flow in butt friction stir welds in AA2024-T3, H.N.B. Schmidt,
T.L. Dickerson, J.H. Hattel, Acta Materialia, pp 1199-1209, 2005.
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J.C. McClure, Materials Science and Engineering, pp 213-223, 1999.
14. Influence of pin geometry on material flow in friction stir welding process,
Y.-H. Zhao, S.-B. Lin, F.-X. Qu and L. Wu, Materials Science and
Technology, vol 22, no 1, pp 45-50, 2006.
15. K. Colligan, Material flow behaviour during friction stir welding of
aluminium, Welding Journal vol.78 no.7, pp229-237, Jul. 1999.
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Marker

Insert

Technique,

T.U.SEIDEL,

A.P.REYNOLDS,

METALLURGICAL AND MATERIALS TRANSACTIONS A, vol. 32A, pp

2879-2884, 2001.
17. Judy Schneider, Ronald Beshears, Arthur C. Nunes Jr. Interfacial sticking
and slipping in the friction stir welding process, Materials Science and
Engineering, vol. 435-436, pp. 297-304, Nov. 2006.
18. Validation of Marker Material Flow in 4 mm Thick Friction Stir Welded Al
2024

T351

through

Computer

Microtomography

and

dedicated

Metallographic Techniques, Rudolf Zettler, Tilman Donath, Jorge F. dos

Santos,

Felix

Beckman

and

Daniela

Lohwasser,

ADVANCED

ENGINEERING MATERIALS, pp 68-79, 2006.

19. S.W. Xu, X.M. Deng, A.P.Reynolds, T.U. Seidel, Finite element simulation
of material flowin friction stir welding, Sci.Technol.Weld. Joining 6, pp 340348, 2001.

116

20. H.W. Zhang, Z. Zhang, J.T. Chen, 3D modeling of material flow in friction
stir welding under different process parameters, Journal of Material
Processing Technology, vol. 183, no. 1, pp. 62-67, Mar. 2007.
21. Paul A. Colegrove, Hugh R. Shercliff, 3-Dimensional CFD modelling of flow
round a threaded friction stir welding tool profile, Journal of Materials
Processing Technology 169 (2005) 320327.
22. G.J. Bendzsak, C.B. Smith, in: Proceedings of the Second International
Symposium on Friction Stir Welding, Gothenburg, Sweden, June 2628, 2000.
23. William J. Arbegast, A flow-partitioned deformation zone model for defect
deformation during friction stir welding, vol. 58, pp 372-376, 2007.
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processing using a particle-grid method, Department of Mechanical
Engineering, Brigham Young University, Provo, USA, pp 431443, 2008.
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Hamilton,

Stanislaw

Dymek,

Marek

Blicharski,

Materials

Characterization, A model of material flow during friction stir welding,

2007.
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117