Numerical and experimental investigation of defects formation during friction stir processing on AZ91

Abstract The heat generated during friction stir processing greatly affects defects formation in the processed zone of workpieces. In this paper, numerical modeling process is performed to determine influence tool rotational and traverse speeds hence their ratio on thermal distribution attained process. aim produce defect-free samples by selecting adequate speeds. mechanisms depending peak temperature are also investigated. Experiments verify simulation results were conducted with same parameters. Several 20, 40, 60, 80 mm/min 700, 1000, 1200, 2000 rpm used conducting experiments. From experimental results, it was found that; high-speed conditions (low-generated heat) can such as tunnels grooves, low-speed (high-generated cause flashes. show that speed 1200 60 (speed 20), no macro observed. According these 475 °C. At temperature, material softened, structure finely equiaxed large scale melting appeared zone. developed model be useful investigate occurrence associated different Graphic abstract