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<p>Friction stir welding (FSW) was used to join dissimilar magnesium alloys AZ31 and ZE41, in two configurations, retreating side (RS) and advancing side (AS), and vice versa. The effects of rotational speed and traverse feed on microstructure and mechanical properties were investigated. The ZE41(RS)–AZ31(AS) configuration exhibited superior weld quality, where higher rotational speeds promoted grain refinement through dynamic recrystallization, while increasing feed caused grain coarsening due to reduced tool–material interaction. Energy-dispersive X-ray spectroscopy (EDS) revealed localized enrichment of Zn and Al in the stir zone, indicating the possible formation of Mg–Zn and Mg–Al intermetallic phases resulting from elemental diffusion. Microhardness and tensile results showed improved hardness uniformity, strength, and ductility for ZE41(RS)–AZ31(AS) joints. SEM fractography indicated ductile failure at high rotational speed and low feed, whereas higher feed produced mixed ductile–brittle fracture. These results highlight the importance of material positioning and FSW parameters in optimizing dissimilar magnesium alloy welds.</p>

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Correlation Between Process Parameters and Mechanical Performance of AZ31 and ZE41 Welded Joints in Friction Stir Welding Process

  • 期刊论文

  • 发表日期：

    2026年4月16日

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  • Pradeep Kumar Prathipati,
  • Vamsi Krishna Pasam

摘要

Friction stir welding (FSW) was used to join dissimilar magnesium alloys AZ31 and ZE41, in two configurations, retreating side (RS) and advancing side (AS), and vice versa. The effects of rotational speed and traverse feed on microstructure and mechanical properties were investigated. The ZE41(RS)–AZ31(AS) configuration exhibited superior weld quality, where higher rotational speeds promoted grain refinement through dynamic recrystallization, while increasing feed caused grain coarsening due to reduced tool–material interaction. Energy-dispersive X-ray spectroscopy (EDS) revealed localized enrichment of Zn and Al in the stir zone, indicating the possible formation of Mg–Zn and Mg–Al intermetallic phases resulting from elemental diffusion. Microhardness and tensile results showed improved hardness uniformity, strength, and ductility for ZE41(RS)–AZ31(AS) joints. SEM fractography indicated ductile failure at high rotational speed and low feed, whereas higher feed produced mixed ductile–brittle fracture. These results highlight the importance of material positioning and FSW parameters in optimizing dissimilar magnesium alloy welds.