The soundness and properties of both butt and lap friction stir welds (FSW) are directly related to the material flow around welding tool. The material flow in FSW relies on welding parameters, tool design and thermomechanical properties of base metals. In this work different flow patterns resulting from different welding parameters in butt and lap joint configurations are analyzed with the aim of determining how these different flow patterns can be developed and their impact on final microstructural features and mechanical properties. The effect of rotational speed and tool design (threaded and non-threaded cylindrical pin) is particularly investigated.
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