Abstract
Different morphology and thinning cases of the weld zone of a 7022 aluminum alloy in friction stir welding were analyzed. Metal plastic flow processes in the contact zone for an aerospace friction stir-joint 7022 aluminum alloy were evaluated. The cross section of the contact zon was analyzed by metallographic and tool microscopes. Then, the plastic flow law of the contact zone was established. Theoretical analysis confirmed the validity of the metal plastic flow law and corresponding thinning model of the weld zone. The thinning model for filling due to indirect extrusion–vortex flow can adequately characterize the plastic flow of metals and formation process of thinning in the weld zone.
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