Material flow behavior and microstructural evolution during refill friction stir spot welding of alclad 2A12-T4 aluminum alloy

In this study, we used the stop-action technique to experimentally investigate the material flow and microstructural evolution of al-clad 2A12-T4 aluminum alloy during refill friction stir spot welding. There are two material flow components, i.e., the inward- or outward-directed spiral flow on the horizontal plane and the upward- or downward-directed flow on the vertical plane. In the plunge stage, the flow of plasticized metal into the cavity is similar to that of a stack, whereby the upper layer is pushed upward by the lower layer. In the refill stage, this is process reversed. As such, there is no obvious vertical plasticized metal flow between adjacent layers. Welding leads to the coarsening of S (Al₂CuMg) in the thermo-mechanically affected zone and the diminishing of S in the stir zone. Continuous dynamic recrystallization results in the formation of fine equiaxed grains in the stir zone, but this process becomes difficult in the thermo-mechanically affected zone due to the lower deformation rate and the pinning action of S precipitates on the dislocations and sub-grain boundaries, which leads to a high fraction of low-angle grain boundaries in this zone.