Microstructure and Properties of 5052 Aluminum Alloy Stir Friction Welded Joints

WANG Hongduo; WANG Zilong; CHANG Suteng; ZHOU Zhiyong; LU Yongxin; QIANG Wei

doi:10.3969/j.issn.1674-6457.2025.09.005

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (9) : 60-69. DOI: 10.3969/j.issn.1674-6457.2025.09.005

Light Alloy Forming

Microstructure and Properties of 5052 Aluminum Alloy Stir Friction Welded Joints

WANG Hongduo^*, WANG Zilong¹, CHANG Suteng¹, ZHOU Zhiyong², LU Yongxin¹, QIANG Wei¹

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Abstract

The work aims to investigate the effects of microstructure on mechanical and corrosion properties in friction stir welded (FSW) joints of 3 mm thick 5052 aluminum alloy plates, so as to provide theoretical references for engineering applications. The joint microstructure was characterized by optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM). Microhardness and tensile properties were evaluated via a microhardness tester and an universal testing machine, while strain distribution was analyzed through digital image correlation (DIC). Immersion corrosion tests were conducted in 3.5% NaCl solution. After FSW, the stir zone (SZ) exhibited significant grain refinement with increased high-angle grain boundaries (HAGBs) and recrystallization fraction, along with reduced proportions of low-angle grain boundaries (LAGBs) and kernel average misorientation (KAM) values. The KAM distribution correlated with LAGBs distribution, confirming continuous dynamic recrystallization (CDRX) as the grain refinement mechanism in SZ. The thermo-mechanically affected zone (TMAZ) underwent dynamic recovery and partial recrystallization, whereas the heat-affected zone (HAZ) primarily experienced dynamic recovery, with the advancing side HAZ (HAZ_AS) showing the highest degree of recovery. Hardness distribution revealed the base metal (BM) exhibited the highest hardness, followed by the SZ, while the TMAZ showed medium hardness. The HAZ had lower hardness, with the HAZ_AS being the softest region and the weakest part of the joint. The uneven strain distribution in each zone of the DIC test joint during the tensile process induced stress concentration, causing the joint to fracture. The tensile strength and elongation of the joint were 209 MPa and 17%, respectively. Compared with BM, they were decreased by 8.7% and 10.5%, respectively. The tensile fracture occurred in the HAZ_AS, and the fracture surface exhibited ductile fracture characteristics. Immersion tests identified exfoliation corrosion in both SZ and BM, with SZ exhibiting superior corrosion resistance. The mechanical degradation is attributed to heterogeneous microstructure distribution, while lower LAGBs proportion or KAM values correlate with enhanced corrosion resistance.

Key words

5052 aluminum alloy / FSW / microstructure / CDRX / mechanical properties / corrosion resistance

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WANG Hongduo, WANG Zilong, CHANG Suteng, ZHOU Zhiyong, LU Yongxin, QIANG Wei. Microstructure and Properties of 5052 Aluminum Alloy Stir Friction Welded Joints[J]. Journal of Netshape Forming Engineering. 2025, 17(9): 60-69 https://doi.org/10.3969/j.issn.1674-6457.2025.09.005

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