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<p>This study focuses on how multi-pass friction stir processing (FSP) can help AA6063 alloys achieve grain refinement. According to grain size statistics, FSP considerably refines the AA6063 grain structure, resulting in a more equiaxed grain structure because of increased heat cycling and plastic straining. Grain size decreased from 93.7&#xa0;μm to 9.2&#xa0;μm after the first pass. Further refinement was achieved in subsequent passes, with an 8.7&#xa0;μm result in the second pass and a small coarsening to 9.4&#xa0;μm in the third. SEM examination indicated effective precipitate dissolution and reprecipitation by transforming primary precipitates into finer, more evenly dispersed particles. The Mg<sub>2</sub>Al<sub>3</sub> phase’s stability throughout FSP passes, and its capacity to retain its strengthening action was also validated by EDS analysis. Mechanical tests showed significant improvements in properties: after the second pass, ultimate tensile strength (UTS) increased from 233&#xa0;MPa to 282&#xa0;MPa, and hardness increased from 81.9 HV to 101.5 HV. Nevertheless, more passes resulted in a minor decrease in these attributes. The results showed improved corrosion resistance and ductility, with elongation rising from 18.9% to 25.1% following the second pass. According to the Tafel test results, the corrosion potential significantly improved after the second pass, going from − 1161 mV in the base alloy to -624 mV.</p>

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Microstructural Homogeneity and Property Improvements in AA6063 Through Multi-Pass FSP

  • 期刊论文

  • 发表日期：

    2026年2月20日

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  • Jasper Johnson Dokiburra,
  • R. Madhusudhan,
  • Chitturi Ram Prasad

摘要

This study focuses on how multi-pass friction stir processing (FSP) can help AA6063 alloys achieve grain refinement. According to grain size statistics, FSP considerably refines the AA6063 grain structure, resulting in a more equiaxed grain structure because of increased heat cycling and plastic straining. Grain size decreased from 93.7 μm to 9.2 μm after the first pass. Further refinement was achieved in subsequent passes, with an 8.7 μm result in the second pass and a small coarsening to 9.4 μm in the third. SEM examination indicated effective precipitate dissolution and reprecipitation by transforming primary precipitates into finer, more evenly dispersed particles. The Mg2Al3 phase’s stability throughout FSP passes, and its capacity to retain its strengthening action was also validated by EDS analysis. Mechanical tests showed significant improvements in properties: after the second pass, ultimate tensile strength (UTS) increased from 233 MPa to 282 MPa, and hardness increased from 81.9 HV to 101.5 HV. Nevertheless, more passes resulted in a minor decrease in these attributes. The results showed improved corrosion resistance and ductility, with elongation rising from 18.9% to 25.1% following the second pass. According to the Tafel test results, the corrosion potential significantly improved after the second pass, going from − 1161 mV in the base alloy to -624 mV.