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<p>This study investigates the microstructural and textural evolution of friction stir-processed (FSPed) 6061-O aluminium alloy using electron backscatter diffraction (EBSD). The base material for this study was received as a 100 × 50 × 25 mm bar of 6061-O aluminium alloy. Processing was carried out at a tool rotational speed of 1000 rpm and a traverse speed of 25 mm/min for one, two, and three passes to examine the influence of multiple passes on grain refinement. EBSD analysis revealed a progressive increase in high-angle grain boundaries (HAGB), from 48 % in one pass to 53 % in two passes and 58 % in three passes, while the fraction of low-angle grain boundaries (LAGB) decreased correspondingly from 52 % to 47 % and 42 %, respectively. These changes confirm enhanced recrystallisation and strain-induced boundary migration with additional passes. Texture analysis showed the development of characteristic shear components, mainly C {112}&lt;111&gt; and B {011}&lt;112&gt;, along with partial retention of the Cube {001}&lt;100&gt; orientation. The nugget zone displayed fine, equiaxed grains formed through dynamic recrystallisation, marking a clear transformation from the elongated grains of the annealed base metal to a much finer and uniform structure. A reduction in overall texture intensity was observed under multi-pass conditions, suggesting enhanced recovery and subgrain coalescence during repeated thermo-mechanical cycling. The combined effect of severe plastic deformation and frictional heating produced a homogeneous, fully recrystallised microstructure with stable texture, demonstrating the effectiveness of FSP in generating ultrafine-grained 6061-O aluminium alloy with improved structural uniformity.</p>

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Multi-pass friction stir processing of AA6061-O alloy: Process-structure-mechanical property relationship

  • 期刊论文

  • 发表日期：

    2026年6月3日

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  • Nowsath Begam M. Y.,
  • Balasundaram R.

摘要

This study investigates the microstructural and textural evolution of friction stir-processed (FSPed) 6061-O aluminium alloy using electron backscatter diffraction (EBSD). The base material for this study was received as a 100 × 50 × 25 mm bar of 6061-O aluminium alloy. Processing was carried out at a tool rotational speed of 1000 rpm and a traverse speed of 25 mm/min for one, two, and three passes to examine the influence of multiple passes on grain refinement. EBSD analysis revealed a progressive increase in high-angle grain boundaries (HAGB), from 48 % in one pass to 53 % in two passes and 58 % in three passes, while the fraction of low-angle grain boundaries (LAGB) decreased correspondingly from 52 % to 47 % and 42 %, respectively. These changes confirm enhanced recrystallisation and strain-induced boundary migration with additional passes. Texture analysis showed the development of characteristic shear components, mainly C {112}<111> and B {011}<112>, along with partial retention of the Cube {001}<100> orientation. The nugget zone displayed fine, equiaxed grains formed through dynamic recrystallisation, marking a clear transformation from the elongated grains of the annealed base metal to a much finer and uniform structure. A reduction in overall texture intensity was observed under multi-pass conditions, suggesting enhanced recovery and subgrain coalescence during repeated thermo-mechanical cycling. The combined effect of severe plastic deformation and frictional heating produced a homogeneous, fully recrystallised microstructure with stable texture, demonstrating the effectiveness of FSP in generating ultrafine-grained 6061-O aluminium alloy with improved structural uniformity.