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A variety of tool shoulder designs comprising three families i.e. blade, spiral and circular shaped scrolls, were produced to improve the material flow and restrictions to avoid the tunnel void. The bobbin tools were manufactured by 3D printing additive manufacturing technology using solid filament. The butt weld joint was produced by each tool using plasticine as the workpiece material. The apparent surface features and bi-colour cross-sections provided a physical flow comparison among the shoulder designs. For the bobbin friction stir welding (BFSW), the tool shoulder with a three-spiral design produced the most stability with the best combination of the flow patterns on surface and cross-sections. The circular family tools showed a suitable intermixing on the surface pattern, while the blade scrolls showed better flow features within the cross-sections. The flow-driven effect of the shoulder features of the bobbin-tool design (inscribed grooves) was replicated by the 3D-printed tools and the analogue modelling of the weld samples. Similar flow patterns were achieved by dissimilar aluminium-copper weld, validating the accuracy of the analogue plasticine for the flow visualization of the bobbin friction stir welding.

3D-Printed Tool Shoulder Design for the Analogue Modelling of Bobbin Friction Stir Weld Joint Quality