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<p>The present work investigates the enhancement of mechanical properties and microstructural evolution of 6061-O Al alloy subjected to friction stir processing (FSP) using a tungsten carbide (WC) tool. FSP was performed on a vertical CNC milling machine (KODI) with processing factors of tool rotational speeds (700, 1000, and 1300&#xa0;rpm), table travel speeds (25, 45, and 65&#xa0;mm/min), and the number of passes (1, 2, and 3). The experimental work employed the Taguchi Orthogonal L27 design for an investigation. To study the microstructural characterization, optical microscopy (OM), x-ray diffraction (XRD) and electron backscatter diffraction (EBSD) were carried out. XRD patterns indicated progressive peak broadening and a slight shift of 1.15% from the base material, demonstrating asymmetry and lattice strain in the processed region. EBSD demonstrated grain refinement and texture evolution modifications in the stir zone, with a decrease in Grain Orientation Spread (GOS) and kernel average misorientation (KAM), which indicates dynamic recrystallization. Microhardness testing revealed a significant increase in hardness at the stir zone with a peak value of 63&#xa0;HV<sub>0.3</sub>, and its 34% increased to the base material observed at a combination of 1000&#xa0;rpm and 25&#xa0;mm/min during the third pass, attributed to refined grains and strain hardening effects The texture index (TI) decreased from 13.94 to 3.61 after the third pass FSP, indicating a weakening of grain orientation and crystallographic texture, confirming a more isotropic microstructure. ANOVA showed that the number of passes contributed ≈ 59% to tensile strength improvement, and the regression model (<i>R</i><sup>2</sup> = 98.7%) predicted UTS with &lt; 5% error, confirming high reliability in optimizing FSP parameters. These findings demonstrate that FSP is an efficient method for tailoring the microstructure and enhancing the mechanical performance of 6061-O alloys.</p>

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Investigations of Microstructural and Texture Evolution in Friction Stir-Processed 6061-O Al Alloy

  • 期刊论文

  • 发表日期：

    2026年7月23日

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  • M Y Nowsath Begam,
  • R. Balasundaram

摘要

The present work investigates the enhancement of mechanical properties and microstructural evolution of 6061-O Al alloy subjected to friction stir processing (FSP) using a tungsten carbide (WC) tool. FSP was performed on a vertical CNC milling machine (KODI) with processing factors of tool rotational speeds (700, 1000, and 1300 rpm), table travel speeds (25, 45, and 65 mm/min), and the number of passes (1, 2, and 3). The experimental work employed the Taguchi Orthogonal L27 design for an investigation. To study the microstructural characterization, optical microscopy (OM), x-ray diffraction (XRD) and electron backscatter diffraction (EBSD) were carried out. XRD patterns indicated progressive peak broadening and a slight shift of 1.15% from the base material, demonstrating asymmetry and lattice strain in the processed region. EBSD demonstrated grain refinement and texture evolution modifications in the stir zone, with a decrease in Grain Orientation Spread (GOS) and kernel average misorientation (KAM), which indicates dynamic recrystallization. Microhardness testing revealed a significant increase in hardness at the stir zone with a peak value of 63 HV0.3, and its 34% increased to the base material observed at a combination of 1000 rpm and 25 mm/min during the third pass, attributed to refined grains and strain hardening effects The texture index (TI) decreased from 13.94 to 3.61 after the third pass FSP, indicating a weakening of grain orientation and crystallographic texture, confirming a more isotropic microstructure. ANOVA showed that the number of passes contributed ≈ 59% to tensile strength improvement, and the regression model (R2 = 98.7%) predicted UTS with < 5% error, confirming high reliability in optimizing FSP parameters. These findings demonstrate that FSP is an efficient method for tailoring the microstructure and enhancing the mechanical performance of 6061-O alloys.