In friction stir welding (FSW), a rotating threaded pin tool is
inserted into a weld seam and literally stirs the edges of the seam
together. To determine optimal processing parameters for producing
a defect free weld, a better understanding of the resulting metal
deformation flow path is required. Marker studies are the principal
method of studying the metal deformation flow path around the FSW
pin tool. In our study, we have used computed tomography (CT) scans
to reveal the flow pattern of a lead wire embedded in a FSW weld
seam. At the welding temperature of aluminum, the lead becomes
molten and is carried with the macro-flow of the weld metal. By
using CT images, a 3-dimensional (3D) image of the lead flow
pattern can be reconstructed. CT imaging was found to be a
convenient and comprehensive way of collecting and displaying
tracer data. It marks an advance over previous more tedious and
ambiguous radiographic/metallographic data collection methods.
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