To eliminate the casting defects in the ZL210 aluminum alloys, the active–passive filling friction stir repairing (A-PFFSR) was used. Shoulder morphologies on the surfaces of the pinless tools were designed and optimized to improve the mechanical properties of the repairing joints. The detailed microstructures, interface behaviors, microhardness, and mechanical properties were investigated. The casting defect was first drilled into a keyhole shape by a threaded pin. The keyhole defect was successfully filled by the materials surrounding the keyhole and an extra filler via the A-PFFSR using pinless tools with grooves on the shoulder surface. Increasing the number of groove was beneficial in improving frictional heat and eliminating interfacial defects. The extremely higher heat input easily resulted in severe joint softening. The filling zone consisted of the finer and more uniform grains, leading to the higher microhardness values. The maximum tensile strength of the optimized joint was quasi equivalent to that of base metal.

为了消除ZL210铝合金的铸造缺陷，使用了主动-被动填充摩擦搅拌修复（A-PFFSR）。设计并优化了无针工具表面的肩部形态，以改善修复接头的机械性能。详细的微观结构，界面行为，显微硬度和力学性能进行了调查。首先用螺纹销将铸造缺陷钻成钥匙孔形状。锁孔缺陷是由锁孔周围的材料和A-PFFSR通过使用无销钉工具，在肩部表面带有凹槽的多余填充物成功填充的。增加凹槽的数量有利于改善摩擦热并消除界面缺陷。极高的热量输入很容易导致接头软化。填充区由更细和更均匀的晶粒组成，导致更高的显微硬度值。优化接头的最大抗拉强度近似等于贱金属。