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Bobbin Friction Stir Welding (BFSW) is a thermomechanical process containing severe plastic deformation by mechanical stirring and Dynamic Recrystallization (DRX) during recooling. Here we report the three-dimensional characteristics of the micro-flow patterns within the aluminium weld structure. The Surface topography observations by Atomic Force Microscopy (AFM) show the stirred-induced microstructural evolution where the rearrangement of dislocations at the sub-grain scale, and the subsequent High- and Low-Angle Grain Boundaries (HAGBs, LAGBs) exhibit specific alterations in grain size and morphology of the weld texture. The dislocations interaction in different regions of the weld structure also was observed in correlation to the thermomechanical behaviour of the BFSW process. These micro-flow observations within the weld breadth give a new insight into the thermomechanical characteristics of the FSW process during the stirring action where the plastic flow has a key role in the formation of the weld region distinct from the base metal.

AFM Characterization of Stir-Induced Micro-Flow Features within the AA6082-T6 BFSW Welds