Abstract
The aim of the present article is to offer insight into the effects of pin profiles on interface defects, tensile shear properties, microstructures, and the material flow of friction stir lap welded joints. The results indicate that, compared to the lap joints welded by the single threaded plane pin, the three-plane threaded pin, and the triangle threaded pin, the lap joint obtained by the conventional conical threaded pin is characterized by the minimum interface defect. The alternate threads and planes on the pin provide periodical stress, leading to pulsatile material flow patterns. Under the effect of pulsatile revolutions, an asymmetrical flow field is formed around the tool. The threads on the pin force the surrounding material to flow downward. The planes cannot only promote the horizontal flow of the material by scraping, but also provide extra space for the material vertical flow. A heuristic model is established to describe the material flow mechanism during friction stir lap welding under the effect of pulsatile revolutions.
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