Microstructural modification and mechanical property improvement in friction stir zone of thixo-molded AE42 Mg alloy

Thixo-molded AE42 Mg alloy was friction stir welded, and the soundness of joints was evaluated, together with the microstructure evolution and mechanical properties in friction stir zones. According to X-ray radiography, the optimum FSW condition range of AE42 alloy exists between AZ61 and AZ31 alloys, and it seems that the optimum welding condition range increases with decreasing Al content in the Mg alloys. There are mainly two kinds of compounds in the thixo-molded AE42 alloy, and FSW has little influence on the grainy Al₁₀RE₂Mn₇ compound, but it has great influence on Al₁₁RE₃ phase, which is changed from lamellar eutectic to small particles after welding. Furthermore, the average diameter of Al₁₁RE₃ particles in SZ decreases with increasing the traveling speed at constant rotation speed due to less heat input. The hardness in SZ is higher than that in BM, and tensile strength and elongation are both improved after welding because the stirring refines and uniforms the microstructure and intermetallic compounds.