Pre-weld friction stir processing mitigates hot cracking and strengthens AA6061 fusion welds
Abstract Hot cracking remains a significant challenge in the fusion welding of high-strength aluminum alloys, particularly AA6061, which is highly susceptible to solidification cracking in the fusion zone (FZ). This study investigates the efficacy of friction stir processing (FSP) as a pre-weld trea...
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Nature Portfolio
2025-05-01
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| Series: | Scientific Reports |
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| Online Access: | https://doi.org/10.1038/s41598-025-99424-8 |
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| author | Ali Jalili Ali Ghasemi Mehran Torabi Kafshgari Swee Leong Sing Majid Pouranvari |
| author_facet | Ali Jalili Ali Ghasemi Mehran Torabi Kafshgari Swee Leong Sing Majid Pouranvari |
| author_sort | Ali Jalili |
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| description | Abstract Hot cracking remains a significant challenge in the fusion welding of high-strength aluminum alloys, particularly AA6061, which is highly susceptible to solidification cracking in the fusion zone (FZ). This study investigates the efficacy of friction stir processing (FSP) as a pre-weld treatment to enhance the weldability of AA6061 by engineering the base metal microstructure. We demonstrate that FSP transforms AA6061 from a material highly prone to solidification cracking into one with remarkable crack resistance during fusion welding. By applying multi-pass FSP to AA6061-T6, we achieved a base metal with ultra-fine grains, which facilitated the epitaxial growth of fine grains during subsequent fusion welding. The refined grain structure in the FZ, combined with reduced dendrite arm spacing, significantly mitigated solidification cracking by improving grain coalescence and strain accommodation during solidification. Post-weld T6 heat treatment resulted in a joint efficiency of 0.95 in tensile strength, outperforming conventional fusion welding and friction stir welding. This work highlights the potential of FSP as a pre-weld treatment to convert crack-prone aluminum alloys into viable candidates for high-integrity, lightweight structural applications. |
| format | Article |
| id | doaj-art-3c9fb2a7398d47c48ed1a40d16c35de6 |
| institution | OA Journals |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Nature Portfolio |
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| series | Scientific Reports |
| spelling | doaj-art-3c9fb2a7398d47c48ed1a40d16c35de62025-08-20T02:15:11ZengNature PortfolioScientific Reports2045-23222025-05-0115111010.1038/s41598-025-99424-8Pre-weld friction stir processing mitigates hot cracking and strengthens AA6061 fusion weldsAli Jalili0Ali Ghasemi1Mehran Torabi Kafshgari2Swee Leong Sing3Majid Pouranvari4Department of Materials Science and Engineering, Sharif University of TechnologyDepartment of Mechanical Engineering, College of Design and Engineering, National University of SingaporeDepartment of Materials Science and Engineering, Sharif University of TechnologyDepartment of Mechanical Engineering, College of Design and Engineering, National University of SingaporeDepartment of Materials Science and Engineering, Sharif University of TechnologyAbstract Hot cracking remains a significant challenge in the fusion welding of high-strength aluminum alloys, particularly AA6061, which is highly susceptible to solidification cracking in the fusion zone (FZ). This study investigates the efficacy of friction stir processing (FSP) as a pre-weld treatment to enhance the weldability of AA6061 by engineering the base metal microstructure. We demonstrate that FSP transforms AA6061 from a material highly prone to solidification cracking into one with remarkable crack resistance during fusion welding. By applying multi-pass FSP to AA6061-T6, we achieved a base metal with ultra-fine grains, which facilitated the epitaxial growth of fine grains during subsequent fusion welding. The refined grain structure in the FZ, combined with reduced dendrite arm spacing, significantly mitigated solidification cracking by improving grain coalescence and strain accommodation during solidification. Post-weld T6 heat treatment resulted in a joint efficiency of 0.95 in tensile strength, outperforming conventional fusion welding and friction stir welding. This work highlights the potential of FSP as a pre-weld treatment to convert crack-prone aluminum alloys into viable candidates for high-integrity, lightweight structural applications.https://doi.org/10.1038/s41598-025-99424-8Solidification crackingLiquation crackingFriction stir processingAA6061 aluminum alloy |
| spellingShingle | Ali Jalili Ali Ghasemi Mehran Torabi Kafshgari Swee Leong Sing Majid Pouranvari Pre-weld friction stir processing mitigates hot cracking and strengthens AA6061 fusion welds Scientific Reports Solidification cracking Liquation cracking Friction stir processing AA6061 aluminum alloy |
| title | Pre-weld friction stir processing mitigates hot cracking and strengthens AA6061 fusion welds |
| title_full | Pre-weld friction stir processing mitigates hot cracking and strengthens AA6061 fusion welds |
| title_fullStr | Pre-weld friction stir processing mitigates hot cracking and strengthens AA6061 fusion welds |
| title_full_unstemmed | Pre-weld friction stir processing mitigates hot cracking and strengthens AA6061 fusion welds |
| title_short | Pre-weld friction stir processing mitigates hot cracking and strengthens AA6061 fusion welds |
| title_sort | pre weld friction stir processing mitigates hot cracking and strengthens aa6061 fusion welds |
| topic | Solidification cracking Liquation cracking Friction stir processing AA6061 aluminum alloy |
| url | https://doi.org/10.1038/s41598-025-99424-8 |
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