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<p>This study investigates the metallurgical response of AA6063 joints produced by refill friction stir spot welding (RFSSW) to post-weld heat treatments (PWHTs). Two PWHT strategies were applied: artificial aging (AA) and a solution treatment followed by artificial aging (STAA). The AA treatment significantly improved joint strength, yielding a 15.87% increase in peak load (4.60 kN) and a 92.86% increase in displacement (1.08 mm), compared to the as-welded (AW) condition (3.97 kN and 0.56 mm). The STAA condition further enhanced ductility, with a remarkable 332.14% increase in displacement (2.42 mm). Microhardness profiles revealed peak values in the stir zone (SZ) ranging from 67 to 80 HV, attributed to severe plastic deformation and localized thermal input reaching 435 °C, while the thermo-mechanically affected zone (TMAZ) and heat-affected zone (HAZ) exhibited lower hardness values (62 HV and 57 HV, respectively), reflecting reduced strain and thermal exposure. PWHTs significantly improve fatigue endurance, especially at low displacement (0.1 mm), with both AA and STAA samples exceeding 50,000 cycles, far surpassing the AW sample performance of 2506 cycles. However, under load-controlled conditions (2.5 kN), PWHTs had a detrimental effect on fatigue life, with the AW samples exhibiting the highest durability. In contrast, the STAA joint demonstrated superior ductility, making it a promising option for applications requiring higher deformation tolerance despite its relatively lower fatigue life. Fractographic analysis confirmed that the AW configuration suffers from weak interfacial bonding and limited ductility, leading to premature failure, whereas PWHTs improve plasticity, shifting the fracture mode to nugget pullout.</p>

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Metallurgical response of AA6063 refill friction stir spot welded joints to post-weld heat treatments

  • 期刊论文

  • 发表日期：

    2025年9月8日

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  • Houssem Eddine Lakache,
  • Chourouk Merazga,
  • Adel Belattar,
  • Abdelghani May

摘要

This study investigates the metallurgical response of AA6063 joints produced by refill friction stir spot welding (RFSSW) to post-weld heat treatments (PWHTs). Two PWHT strategies were applied: artificial aging (AA) and a solution treatment followed by artificial aging (STAA). The AA treatment significantly improved joint strength, yielding a 15.87% increase in peak load (4.60 kN) and a 92.86% increase in displacement (1.08 mm), compared to the as-welded (AW) condition (3.97 kN and 0.56 mm). The STAA condition further enhanced ductility, with a remarkable 332.14% increase in displacement (2.42 mm). Microhardness profiles revealed peak values in the stir zone (SZ) ranging from 67 to 80 HV, attributed to severe plastic deformation and localized thermal input reaching 435 °C, while the thermo-mechanically affected zone (TMAZ) and heat-affected zone (HAZ) exhibited lower hardness values (62 HV and 57 HV, respectively), reflecting reduced strain and thermal exposure. PWHTs significantly improve fatigue endurance, especially at low displacement (0.1 mm), with both AA and STAA samples exceeding 50,000 cycles, far surpassing the AW sample performance of 2506 cycles. However, under load-controlled conditions (2.5 kN), PWHTs had a detrimental effect on fatigue life, with the AW samples exhibiting the highest durability. In contrast, the STAA joint demonstrated superior ductility, making it a promising option for applications requiring higher deformation tolerance despite its relatively lower fatigue life. Fractographic analysis confirmed that the AW configuration suffers from weak interfacial bonding and limited ductility, leading to premature failure, whereas PWHTs improve plasticity, shifting the fracture mode to nugget pullout.