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<p>This study investigates the microstructural evolution and mechanical response of laser powder bed fused (L-PBF) AlSi10Mg alloy subjected to single- and multi-pass friction stir processing (FSP), focusing on the formation of concentric banded structures (onion rings) within the stir zone. One- and three-pass FSP were performed under identical parameters, and the resulting microstructures were characterized using optical, scanning, and transmission electron microscopy, and electron backscatter diffraction, followed by hardness testing to evaluate mechanical response. Both conditions produced onion ring patterns characterized by periodic variations in silicon particle size, distribution, and subtle texture changes, arising from complex material flow and thermal cycling. One-pass FSP refined the as-printed microstructure into ultrafine equiaxed grains (1.1 ± 0.3&#xa0;<i>μ</i>m) and fragmented the eutectic Si network, reducing the Si phase area fraction from 17.1% to 8.6%. In contrast, three-pass FSP caused moderate grain coarsening (1.9 ± 0.4&#xa0;<i>μ</i>m) and an increase in Si phase fraction to 17.0% due to particle coarsening and redistribution. These microstructural transformations resulted in hardness reduction from 101 ± 3 HRE to 64 ± 2 HRE after one-pass, followed by partial recovery to 67 ± 1 HRE after three-pass FSP. The findings reveal that multi-pass FSP can effectively tailor the microstructure and hardness of L-PBF-AlSi10Mg.</p>

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Friction Stir Processing-Induced Microstructural Banding in Laser Powder Bed Fused AlSi10Mg

  • 期刊论文

  • 发表日期：

    2026年1月14日

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  • Mahya Ghaffari,
  • Yahya Aghayar,
  • Alireza Vahedi Nemani,
  • Parisa Fathi,
  • Khashayar Morshedbehbahani,
  • Mehran Rafieazad,
  • Mohsen Mohammadi,
  • Adrian Gerlich,
  • Amir Hadadzadeh,
  • Ali Nasiri

摘要

This study investigates the microstructural evolution and mechanical response of laser powder bed fused (L-PBF) AlSi10Mg alloy subjected to single- and multi-pass friction stir processing (FSP), focusing on the formation of concentric banded structures (onion rings) within the stir zone. One- and three-pass FSP were performed under identical parameters, and the resulting microstructures were characterized using optical, scanning, and transmission electron microscopy, and electron backscatter diffraction, followed by hardness testing to evaluate mechanical response. Both conditions produced onion ring patterns characterized by periodic variations in silicon particle size, distribution, and subtle texture changes, arising from complex material flow and thermal cycling. One-pass FSP refined the as-printed microstructure into ultrafine equiaxed grains (1.1 ± 0.3 μm) and fragmented the eutectic Si network, reducing the Si phase area fraction from 17.1% to 8.6%. In contrast, three-pass FSP caused moderate grain coarsening (1.9 ± 0.4 μm) and an increase in Si phase fraction to 17.0% due to particle coarsening and redistribution. These microstructural transformations resulted in hardness reduction from 101 ± 3 HRE to 64 ± 2 HRE after one-pass, followed by partial recovery to 67 ± 1 HRE after three-pass FSP. The findings reveal that multi-pass FSP can effectively tailor the microstructure and hardness of L-PBF-AlSi10Mg.