The influence of multi-pass friction stir processing on the microstructural and mechanical properties of Aluminum Alloy 6082

Samples with one through three passes with 100% overlap were created using friction stir processing (FSP) in order to locally modify the microstructural and mechanical properties of 6082-T6 Aluminum Alloy. A constant rotational speed and three different traverse speeds were used for processing. In this article, the microstructural properties in terms of grain structure and second phase particles distribution, and also the mechanical properties in terms of hardness and tensile strength of the processed zone were addressed with respect to the number of passes and traverse speeds. The parameter combination which resulted in highest ultimate tensile strength was further compared with additional two rotation speeds. FSP caused dynamic recrystallization of the stir zone leading to equiaxed grains with high angle grain boundaries which increased with increasing the number of passes. The accumulated heat accompanying multiple passes resulted in increase in the grain size, dissolution of precipitates and fragmentation of second phase particles. Increasing the traverse speed on the other hand did not affect the grain size, yet reduced the particles size as well as increased the particle area fraction. Hardness and tensile test results of the stir zone were in good agreement where increasing the number of passes caused softening and reduction of the ultimate tensile strength, whereas, increasing the traverse speed increased the strength and hardness. Increasing the tool rotational speed did not have a significant influence on particle mean diameter, ultimate tensile strength and hardness values of the stir zone, whereas, it caused an increase in mean grain size as well as particle area fraction.