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<p>Friction Stir Processing (FSP) is an effective technique to refine microstructures and improve the weldability of crack-prone aluminum alloys such as AA6061. However, this study reveals that during fusion welding of FSP-treated AA6061, abnormal grain growth (AGG) can occur due to prolonged thermal exposure, especially in the heat-affected and partially melted zones. AGG compromises microstructural uniformity and promotes liquation and solidification cracking, diminishing the crack resistance benefits of FSP. Experimental results demonstrate that while FSP suppresses cracking in short welds, extended weld lengths increase thermal accumulation, intensifying AGG and crack susceptibility. These findings emphasize the critical need for precise control of welding parameters and thermal management to maintain microstructural stability and joint integrity. Effective mitigation of AGG through alloy design, process optimization, and heat input control is essential to fully leverage the potential of FSP in advanced manufacturing and fusion welding applications.</p>

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Abnormal Grain Growth Limits Weldability of Friction Stir-Processed Alloys

  • 期刊论文

  • 发表日期：

    2025年9月11日

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  • Ali Jalili,
  • Ali Ghasemi,
  • Mehran Torabi Kafshgari,
  • Majid Pouranvari

摘要

Friction Stir Processing (FSP) is an effective technique to refine microstructures and improve the weldability of crack-prone aluminum alloys such as AA6061. However, this study reveals that during fusion welding of FSP-treated AA6061, abnormal grain growth (AGG) can occur due to prolonged thermal exposure, especially in the heat-affected and partially melted zones. AGG compromises microstructural uniformity and promotes liquation and solidification cracking, diminishing the crack resistance benefits of FSP. Experimental results demonstrate that while FSP suppresses cracking in short welds, extended weld lengths increase thermal accumulation, intensifying AGG and crack susceptibility. These findings emphasize the critical need for precise control of welding parameters and thermal management to maintain microstructural stability and joint integrity. Effective mitigation of AGG through alloy design, process optimization, and heat input control is essential to fully leverage the potential of FSP in advanced manufacturing and fusion welding applications.