Material flow and core/multi-shell structures in a friction stir welded aluminum alloy with embedded copper markers

The objective of this study was to reveal the material flow and temperature distribution in a thick aluminum plate during friction stir welding and examine the subsequent microstructural change with particular attention to the reaction between copper marker and aluminum matrix. It is shown that the material adjacent to the threaded pin was transported from the top to bottom non-symmetrically, and then was forced to move upwards at a small distance from the pin due to the constraint of an extrusion-die-like configuration. The interaction between the copper marker and aluminum matrix led to the formation of (i) a unique core/multi-shell microstructure consisting of copper core, inner shell of AlCu and outer shell of Al2Cu, and (ii) a composite band containing uniformly-distributed Al2Cu particles with refined grains due to the lower stacking fault energy of copper and the pinning role of Al2Cu particles.

► A core/multi-shell structure (Cu core, shells of inner AlCu and outer Al2Cu) occurs.
► A composite structure containing Al2Cu particles with refined grains is formed.
► The material adjacent to the threaded pin flows spirally from the top to bottom.