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In this paper, the effect of different shapes of tool pin on the plastic flow of 2024-T6 aluminum alloy during friction stir welding was studied. In order to observe the plastic flow of materials more clearly, we chose the method of friction stir welding of dissimilar materials, considering the different corrosive characteristics of aluminum alloys made of different materials when exposed to the same corrosive liquid. By studying and comparing the temperature field, macro and microstructure, microhardness and tensile properties of welded joints, the results indicated that the metal in the weld nugget zone (WNZ) mainly came from the base metal of the advancing side, the thread being the driving force of the downward movement of the FSW plastic metal. The deep groove thread tool pin had the strongest ability to drive the metal downward. The conical cam thread tool pin had the strongest stirring effect on materials and the best metal fluidity. The macroscopic morphology, microstructure, mechanical properties and fracture morphology of different joints were analyzed, and the results showed that all joints could form an excellent union, with an onion ring pattern appearing in cross-section. The minimum grain size of the WNZ formed by the conical cam thread stirring head was 7~12 μm; the hardness was least at the junction of the heat affected zone (HAZ) and the thermo-mechanically affected zone (TMAZ). However, the hardness of the weld formed by the conical cam thread at this point was higher than that of other stirring heads; the tensile strength of all joints was more than 80% of the BM, and the maximum tensile strength of the joint welded by the conical cam thread tool pin was 364.27 MPa, accounting for 86.73% of the base metal (BM). The elongation after break was 14.95%. Tensile fracture morphology analysis showed that all joints were fractured by plastic fracture. [ABSTRACT FROM AUTHOR]

Although copper has excellent thermal conductivity, poor wear resistance seriously limits its development. In this paper, a Cu matrix surface composite material reinforced by FeCoNiCrAl high-entropy alloy particles was prepared by friction stir processing. The microstructure and properties of the composite were investigated. The results showed that both the FSP process and the addition of HEA particles contributed to the refinement of the Cu-matrix grains. A diffusion layer with a width of about 0.8 µm was formed at the interface between the HEA particles and the Cu matrix. Compared with received Cu, the microhardness of Cu matrix in the composites was increased by 69.8%, the wear rate was reduced by 29.7%, and the wear resistance was significantly improved. Mean while, the ductility of the composite was consistent with that of the received Cu, and the thermal conductivity reached 87% of the received Cu. Therefore, this paper provided a new possibility for developing multifunctional structural materials with high wear resistance, high ductility, and high thermal conductivity. • HEA particle reinforced Cu-matrix surface composites were successfully prepared via FSP, and the grain size of the matrix was significantly reduced. • HEA particles and Cu matrix formed a diffusion layer continuous with good interfacial bonding. • Compared with traditional particle reinforcement, HEA particle was an excellent reinforcement particle. • The prepared surface composite has significantly improved wear resistance, while maintaining good ductility and thermal conductivity. [ABSTRACT FROM AUTHOR]