Enhanced Mechanical Properties of Pure Aluminum by Friction Stir Processing

In this work, commercial pure aluminum was subjected to friction stir processing (FSP) up to six passes, then, mechanical properties, electrical conductivity, and microstructure analysis of the processed samples were compared with the initial condition. Better yield strength, ultimate tensile strength, and hardness are achieved after imposing the process. Also, strengthening rate is reduced at the subsequent passes. It was found that hardness magnitude is decreased mildly by getting away from the center. Although material formability is reduced after the first pass, it is grown a little by adding the pass number. The microstructure analysis indicated that application of one pass FSP changes considerably grain size of the annealed aluminum and leads to extreme decrease of the high-angle grain boundaries density which plays the main role in the reduction of electrical conductivity. Addition of FSP pass number leads to increment of dislocations density, transformation of low-angle to high-angle grain boundaries, and the further intersection of shear micro bands, causing improvement of sample formability and electrical conductivity compared to the first pass. Therefore, this process has the capability for fabrication of pure aluminum with improved mechanical properties and acceptable electrical conductivity.