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<p>This study introduces a novel, quantitative approach to evaluate weld quality in AA2024-T3 aluminum alloys by analyzing three image-based microstructure parameters: average single-phase area (AASP), phase ratio (PR%), and number of single-phase zones (NSPZ). Using scanning electron microscopy (SEM) image processing and X-ray diffraction (XRD) phase mapping, we correlate these parameters with mechanical properties in tungsten inert gas and friction-stir-processed (TIG + FSP) joints with ER4047 filler. Key findings reveal that TIG + FSP joints achieve 38% higher tensile strength (310&#xa0;MPa vs. 225&#xa0;MPa for TIG), attributed to:</p><p>• Fine-grained homogeneity (AASP reduced by 52–55%),</p><p>• Optimal phase balance (PR% ≈ 50–60%), and.</p><p>• Enhanced phase dispersion (NSPZ increased by 88–143%).</p><p>XRD analysis confirms that FSP redistributes strengthening phases (Al₂Cu, Al₂CuMg) and mitigates Si segregation, explaining the mechanical improvements. Unlike subjective expert-based methods, our approach provides a repeatable, objective framework for weld quality assessment, with direct applications in aerospace and automotive industries.</p>

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Advance analysis of aluminum alloy welded joints microstructure

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年12月19日

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  • Farqad Rasheed Saeed,
  • Jihad Ghanim Abdulkader,
  • Hussein Fawzi Hussein

摘要

This study introduces a novel, quantitative approach to evaluate weld quality in AA2024-T3 aluminum alloys by analyzing three image-based microstructure parameters: average single-phase area (AASP), phase ratio (PR%), and number of single-phase zones (NSPZ). Using scanning electron microscopy (SEM) image processing and X-ray diffraction (XRD) phase mapping, we correlate these parameters with mechanical properties in tungsten inert gas and friction-stir-processed (TIG + FSP) joints with ER4047 filler. Key findings reveal that TIG + FSP joints achieve 38% higher tensile strength (310 MPa vs. 225 MPa for TIG), attributed to:

• Fine-grained homogeneity (AASP reduced by 52–55%),

• Optimal phase balance (PR% ≈ 50–60%), and.

• Enhanced phase dispersion (NSPZ increased by 88–143%).

XRD analysis confirms that FSP redistributes strengthening phases (Al₂Cu, Al₂CuMg) and mitigates Si segregation, explaining the mechanical improvements. Unlike subjective expert-based methods, our approach provides a repeatable, objective framework for weld quality assessment, with direct applications in aerospace and automotive industries.