Improving the Microstructure and Mechanical Properties of a Cast Mg-9Al-1Zn Alloy Using Friction Stir Processing

Friction stir processing (FSP) is a novel thermo-mechanical technique for modifying the microstructure of metals and alloys at targeted locations. In the present study, the microstructures and mechanical properties of friction stir processed Mg-9Al-1Zn (AZ91) alloy were evaluated. 4 mm thick sand cast AZ91 plates with a coarse dendritic microstructure and visible intermetallic phase were processed using single-pass FSP with different combinations of tool rotational and traverse speeds. Significant grain refinement (<10 μm), elimination of casting defects and the dissolution of intermetallic phase were observed at the stir zone (SZ) of all tested specimens. Microhardness tests showed increased microhardness along the SZ with a more uniform microhardness profile as compared to the regions outside the SZ. Mechanical properties evaluation using shear punch testing and subsequent microstructure analysis performed using scanning electron microscopy and microchemical analysis using Energy Dispersive Spectroscopy are discussed in this paper.