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<p>This study investigates the friction stir welding of semi-solid metal 6082 (SSM 6082), produced by rheocasting to attain a globular microstructure prior to joining. The influence of tool rotation and welding speed on heat input, microstructural evolution, and mechanical characteristics was thoroughly investigated at rotation rates of 570, 910, and 1500&#xa0;rpm and welding speeds of 30, 75, and 113&#xa0;mm/min. The weld quality was evaluated using surface inspection, optical and SEM-EDS characterization, tensile testing, bending measurements, and microhardness profiling. Appropriate heat input enabled dynamic recrystallization and uniform redistribution of Mg<sub>2</sub>Si precipitates in the stir zone, whereas insufficient or excessive heat led to particle agglomeration, hook flaws, voids, and softening in the heat-affected zone. The optimal rotation speed of 910&#xa0;rpm and welding speed of 113&#xa0;mm/min produced a maximum tensile strength of 158&#xa0;MPa, along with enhanced ductility, refined equiaxed grains, and a perfect weld nugget. Bending investigations revealed asymmetric distortion between the face and root sides, while microhardness measurements displayed the typical W-shaped profile of friction stir welded aluminum alloys. The results demonstrate that careful management of thermal and mechanical inputs enhances the effective utilization of the semi-solid microstructure, offering a feasible approach for joining and shaping SSM-based aluminum alloys in structural and lightweight engineering applications.</p>

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Novel investigation of friction stir welding of rheocast semi-solid metal 6082 (SSM6082): effects on metallurgical structure and mechanical properties

  • 期刊论文

  • 发表日期：

    2026年3月31日

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  • Worapong Boonchouytan,
  • Kittima Sillapasa

摘要

This study investigates the friction stir welding of semi-solid metal 6082 (SSM 6082), produced by rheocasting to attain a globular microstructure prior to joining. The influence of tool rotation and welding speed on heat input, microstructural evolution, and mechanical characteristics was thoroughly investigated at rotation rates of 570, 910, and 1500 rpm and welding speeds of 30, 75, and 113 mm/min. The weld quality was evaluated using surface inspection, optical and SEM-EDS characterization, tensile testing, bending measurements, and microhardness profiling. Appropriate heat input enabled dynamic recrystallization and uniform redistribution of Mg2Si precipitates in the stir zone, whereas insufficient or excessive heat led to particle agglomeration, hook flaws, voids, and softening in the heat-affected zone. The optimal rotation speed of 910 rpm and welding speed of 113 mm/min produced a maximum tensile strength of 158 MPa, along with enhanced ductility, refined equiaxed grains, and a perfect weld nugget. Bending investigations revealed asymmetric distortion between the face and root sides, while microhardness measurements displayed the typical W-shaped profile of friction stir welded aluminum alloys. The results demonstrate that careful management of thermal and mechanical inputs enhances the effective utilization of the semi-solid microstructure, offering a feasible approach for joining and shaping SSM-based aluminum alloys in structural and lightweight engineering applications.