<p>Friction stir welding (FSW) technology was employed for joining the selective laser melted (SLM) AlSi7Mg specimens, and the microstructures and mechanical properties of welded joints were elucidated. During FSW, the material underwent severe thermo-mechanical coupling effect, resulting in features of the welded zone completely distinct from the SLM base material: pore size and number were significantly reduced, the eutectic Si-rich phase transformed from a continuous network into discrete blocky particles (2–8 μm), and grain coarsening occurred in the heat-affected zone. Notably, the heat-affected zone became a weak position for fracture failure. Based on comprehensive experimental investigations and microstructural analyses, FSW was found to (i) reduce porosity in SLM AlSi7Mg welds by 83.6% and (ii) achieve 81.5% of SLM base material’s tensile strength alongside enhanced microhardness and density—outperforming traditional fusion welds such as argon arc welding. These results confirm the significant potential of FSW for joining SLM aluminum alloy components.</p> Graphical abstract <p></p>

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Investigation of microstructure and mechanical properties of friction stir welded AlSi7Mg alloy fabricated by selective laser melting

  • Lei Wang,
  • Jiaxing Ge,
  • Taolei Wang,
  • Yonggang Wang,
  • Shengzhou Feng,
  • Tianxi Gao,
  • Fangjuan Qi

摘要

Friction stir welding (FSW) technology was employed for joining the selective laser melted (SLM) AlSi7Mg specimens, and the microstructures and mechanical properties of welded joints were elucidated. During FSW, the material underwent severe thermo-mechanical coupling effect, resulting in features of the welded zone completely distinct from the SLM base material: pore size and number were significantly reduced, the eutectic Si-rich phase transformed from a continuous network into discrete blocky particles (2–8 μm), and grain coarsening occurred in the heat-affected zone. Notably, the heat-affected zone became a weak position for fracture failure. Based on comprehensive experimental investigations and microstructural analyses, FSW was found to (i) reduce porosity in SLM AlSi7Mg welds by 83.6% and (ii) achieve 81.5% of SLM base material’s tensile strength alongside enhanced microhardness and density—outperforming traditional fusion welds such as argon arc welding. These results confirm the significant potential of FSW for joining SLM aluminum alloy components.

Graphical abstract