Influence of Friction-Stir-Processing parameters on the microstructure and local mechanical properties of an Aluminium-6% Magnesium-H18 alloy

One major challenge of friction stir processing (FSP) is its sensitivity to parameters like advancing and rotational speeds. This study examined the effect of tool travel speed on the microstructural evolution and mechanical properties of a new-generation Al-6Mg alloy. Optical and electron microscopy, EBSD, and shear-punch testing (SPT) were used. Two travel speeds, 50 and 120 mm/min, revealed significant differences in microstructure and properties at ambient temperature. EBSD provided misorientation maps and boundary fraction data. Microstructure analysis showed continuous dynamic recrystallization in the nugget zone, with finer grains observed at the higher speed. Microhardness was greater on both sides at 120 mm/min. The TMAZ showed elongated grains at 120 mm/min, while recrystallized grains were more prominent at 50 mm/min. In the HAZ, partial recrystallization occurred at 120 mm/min, whereas extensive recrystallization was observed at 50 mm/min. The SPT results indicated variations in stiffness between advancing and retreating sides, especially 2 mm from the nugget center. At 10 and 20 mm from the center, higher stiffness and strength were recorded at 120 mm/min. This study established correlations between joint stiffness, grain misorientation, and travel speed.