Reinforcing the exit hole from friction stir welding and processing

Abstract

After friction stir welding/processing (FSW/P), an exit hole remains at the end of the run, which can be the weakest region of the welded/processed workpiece. In addition, tensile residual stress around the exit hole resulting from heating during FSW/P facilitates incipient crack initiating from the exit hole under external loading. Current solutions include removing or repairing the exit hole, which are time-consuming and costly. Here, we propose a novel method to reinforce the exit hole by applying an additional FSW/P pass around it, in a way that replaces preexisting tensile residual stress with compressive residual stress. Under external loading, there is no evident strain accumulation around the exit hole, and the workpiece ultimately fails along the FSW/P heat affected zone. This method provides a more convenient way to reinforce the exit hole than the current exit-hole repair or removal methods for industrial applications.