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<p>Dissimilar aluminum alloy plates of a novel Al-Zn-Mg-Sc-Zr alloy and an Al-Mg-Si alloy were successfully welded using friction stir welding (FSW). The microstructural characteristics and mechanical properties of the different regions within the joints were systematically investigated. The dissimilar FSW joint exhibits a yield strength (<i>σ</i><sub>0.2</sub>) of 197&#xa0;MPa, an ultimate tensile strength (<i>σ</i><sub>b</sub>) of 232&#xa0;MPa, and an elongation (<i>δ</i><sub>5</sub>) of 4.3%.The results indicate that the heat-affected zone (HAZ) on the Al-Mg-Si side constitutes the mechanical property weak region of the dissimilar welded joint, with a minimum microhardness of 56 HV located approximately 8&#xa0;mm from the weld nugget zone (WNZ) center, representing a softening degree of about 53.1% compared to the Al-Mg-Si base material (BM). This softening is attributed to the transformation of <i>β</i>″ into <i>β</i>′ precipitates during the welding thermal cycle, which diminishes the precipitation strengthening effect. In contrast, the Al-Zn-Mg-Sc-Zr side exhibits limited grain coarsening and minimal recrystallization, as coherent Al<sub>3</sub>(Sc,Zr) particles effectively inhibit recrystallization. The WNZ is predominantly composed of granular <i>α</i>-AlFeMnSi phases exhibiting a body-centered cubic (BCC) structure. Severe lattice mismatch-induced strain is localized at the <i>α</i>-AlFeMnSi/Al interface, predominantly on the Al matrix side, which manifests an interfacial strain accommodation mechanism.</p>

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Microstructure and Mechanical Properties of Dissimilar Friction Stir-Welded Al-Zn-Mg-Sc-Zr/Al-Mg-Si Joints

  • 期刊论文

  • 发表日期：

    2026年6月25日

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  • Fan Zhou,
  • Hu Xie,
  • Jian Ren,
  • Wei Meng

摘要

Dissimilar aluminum alloy plates of a novel Al-Zn-Mg-Sc-Zr alloy and an Al-Mg-Si alloy were successfully welded using friction stir welding (FSW). The microstructural characteristics and mechanical properties of the different regions within the joints were systematically investigated. The dissimilar FSW joint exhibits a yield strength (σ0.2) of 197 MPa, an ultimate tensile strength (σb) of 232 MPa, and an elongation (δ5) of 4.3%.The results indicate that the heat-affected zone (HAZ) on the Al-Mg-Si side constitutes the mechanical property weak region of the dissimilar welded joint, with a minimum microhardness of 56 HV located approximately 8 mm from the weld nugget zone (WNZ) center, representing a softening degree of about 53.1% compared to the Al-Mg-Si base material (BM). This softening is attributed to the transformation of β″ into β′ precipitates during the welding thermal cycle, which diminishes the precipitation strengthening effect. In contrast, the Al-Zn-Mg-Sc-Zr side exhibits limited grain coarsening and minimal recrystallization, as coherent Al3(Sc,Zr) particles effectively inhibit recrystallization. The WNZ is predominantly composed of granular α-AlFeMnSi phases exhibiting a body-centered cubic (BCC) structure. Severe lattice mismatch-induced strain is localized at the α-AlFeMnSi/Al interface, predominantly on the Al matrix side, which manifests an interfacial strain accommodation mechanism.