Liquation and re-solidification in thermo-mechanically affected zone during friction stir spot welding of AZ91 alloy substrate

The present research aims to study the liquation and re-solidification of liquid during friction stir spot welding of AZ91 alloy. Although friction stir spot welding is a solid-state process, the presence of Mg17Al12 intermetallic compounds results in liquation during the welding process. In this study, friction stir spot welding was performed with a tool rotational speed of 2500 rev/min and a tool dwell time of 5 seconds. The microstructural assessment was carried out by optical and scanning electron microscopes. The results showed that initiation of liquation from the inner and outer edge of the eutectic precipitates occurred based on the melting of residual eutectic. Moving toward stirred zone, a liquid film formed along the grain boundaries. The liquid re-solidified as a composite structure of α-Mg/, which α-Mg phase dispersed in γ-Mg17Al12 matrix. Also, the results showed that eutectic morphology resulting from re-solidification is related to the cooling rate. Eutectic morphology changed from granular to fibrous by increasing the cooling rate. Also, the liquid film along the grain boundaries re-solidified as a divorced eutectic.