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<p>This study presents the metallurgical characterization of friction-stir-welded aluminium-4.2%magnesium-0.6%manganese-0.4%scandium-0.1%zirconium alloy plates intended for automotive, naval and marine structures. This research encompasses a mechanical property evaluation, microhardness survey, macro- and microstructural analysis, scanning electron microscopy analysis, tensile fracture analysis, scanning electron microscopy-energy dispersive spectroscopy, X-ray diffraction and corrosion analysis of the friction-stir-welded joints. This investigation delves into the nuanced aspects of weld integrity, offering insights into the structural and mechanical behaviour of the material. The friction stir welding of Al–Mg–Mn alloys under varying process conditions demonstrated significant changes in the mechanical and metallurgical properties. Hardness values in the nugget zone ranged from 97.5 to 116&#xa0;HV10, primarily influenced by grain refinement and the presence of Al–Mg–Mn–Sc–Zr intermetallics. Microstructural analysis showed fine grains in the nugget zone, with uniform distribution of intermetallics, while scanning electron microscopy revealed ductile fracture behaviour. The XRD analysis results confirm that the welding process does not cause any significant phase transformations, but instead promotes the formation and distribution of strengthening phases within the nugget zone. Corrosion testing exhibited minimal variation in corrosion potential, with improved resistance at the optimum conditions, attributed to grain refinement and the formation of a protective oxide layer. The EDS analysis shows that the friction-stir-welding process promotes the dissolution and redistribution of alloying elements, ensuring uniform distribution in the nugget zone, which enhances tensile strength, corrosion resistance, and the formation of strengthening intermetallics. The results contribute to a deeper understanding of weld performance under diverse conditions, laying the foundation for informed decision-making in automotive, naval and marine engineering applications.</p>

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Mechanical and Metallurgical Characterization of Friction Stir Welded Al–Mg–Mn Alloy with Minor Additions of Sc and Zr

  • 期刊论文

  • 发表日期：

    2025年5月28日

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  • Srinivasa Rao Mallipudi,
  • Rajaroy Marampudi

摘要

This study presents the metallurgical characterization of friction-stir-welded aluminium-4.2%magnesium-0.6%manganese-0.4%scandium-0.1%zirconium alloy plates intended for automotive, naval and marine structures. This research encompasses a mechanical property evaluation, microhardness survey, macro- and microstructural analysis, scanning electron microscopy analysis, tensile fracture analysis, scanning electron microscopy-energy dispersive spectroscopy, X-ray diffraction and corrosion analysis of the friction-stir-welded joints. This investigation delves into the nuanced aspects of weld integrity, offering insights into the structural and mechanical behaviour of the material. The friction stir welding of Al–Mg–Mn alloys under varying process conditions demonstrated significant changes in the mechanical and metallurgical properties. Hardness values in the nugget zone ranged from 97.5 to 116 HV10, primarily influenced by grain refinement and the presence of Al–Mg–Mn–Sc–Zr intermetallics. Microstructural analysis showed fine grains in the nugget zone, with uniform distribution of intermetallics, while scanning electron microscopy revealed ductile fracture behaviour. The XRD analysis results confirm that the welding process does not cause any significant phase transformations, but instead promotes the formation and distribution of strengthening phases within the nugget zone. Corrosion testing exhibited minimal variation in corrosion potential, with improved resistance at the optimum conditions, attributed to grain refinement and the formation of a protective oxide layer. The EDS analysis shows that the friction-stir-welding process promotes the dissolution and redistribution of alloying elements, ensuring uniform distribution in the nugget zone, which enhances tensile strength, corrosion resistance, and the formation of strengthening intermetallics. The results contribute to a deeper understanding of weld performance under diverse conditions, laying the foundation for informed decision-making in automotive, naval and marine engineering applications.