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Volume 15
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10.3390/met15101128
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Effects of Tool Rotational Speed on the Microstructure and Properties of Friction Stir Welded AZ61 Magnesium Alloy Joints

by
Xihong Jin
1,
Minjie He
2,
Yongzhang Su
1,
Hongfei Li
1,
Xuhui Feng
2,
Na Xie
2,
Jiaxin Huang
2 and
Jian Peng
2,*
1
CRRC Zhuzhou Electric Locomotive Co., Ltd., Zhuzhou 412001, China
2
National Engineering Research Center for Magnesium Alloys, College of Materials Science and Engineering, Chongqing University, Chongqing 400044, China
*
Author to whom correspondence should be addressed.
Metals 2025, 15(10), 1128; https://doi.org/10.3390/met15101128
Submission received: 9 September 2025 / Revised: 8 October 2025 / Accepted: 9 October 2025 / Published: 10 October 2025
(This article belongs to the Special Issue Perspectives of Joints and Joining Technology Development for Metallic and Hybrid Materials)
Versions Notes

Abstract

Magnesium alloys, characterized by high specific strength and low density, have high potential for applications in transportation and aerospace. Nevertheless, ensuring the reliable joining of thin-walled components remains a major technical challenge. This study examines how rotational speed affects the microstructure and mechanical properties of friction stir welded AZ61 magnesium alloy hollow profiles (3 mm thick), with particular focus on the underlying mechanisms. The results show that higher rotational speed during friction stir welding promotes dynamic recrystallization and weakens the basal texture. It also affects microstructural homogeneity, where an optimal rotational speed produces a relatively uniform hybrid microstructure consisting of refined recrystallized and un-recrystallized regions. This balance enhances both texture strengthening and microstructural optimization. The weld joint fabricated at a rotational speed of 1500 rpm showed the best overall mechanical properties, with ultimate tensile strength, yield strength, and elongation reaching peak values of 286.7 MPa, 154.7 MPa, and 9.7%, respectively. At this speed, the average grain size in the weld nugget zone was 4.92 μm, and the volume fraction of second-phase particles was 0.67%. This study establishes a critical process foundation for the reliable joining of thin-walled magnesium alloy structures. The optimized parameters serve as valuable guidelines for engineering applications in lightweight transportation equipment and aerospace manufacturing.
Keywords: AZ61 magnesium alloy; friction stir welding; microstructure; mechanical performance AZ61 magnesium alloy; friction stir welding; microstructure; mechanical performance

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MDPI and ACS Style

Jin, X.; He, M.; Su, Y.; Li, H.; Feng, X.; Xie, N.; Huang, J.; Peng, J. Effects of Tool Rotational Speed on the Microstructure and Properties of Friction Stir Welded AZ61 Magnesium Alloy Joints. Metals 2025, 15, 1128. https://doi.org/10.3390/met15101128

AMA Style

Jin X, He M, Su Y, Li H, Feng X, Xie N, Huang J, Peng J. Effects of Tool Rotational Speed on the Microstructure and Properties of Friction Stir Welded AZ61 Magnesium Alloy Joints. Metals. 2025; 15(10):1128. https://doi.org/10.3390/met15101128

Chicago/Turabian Style

Jin, Xihong, Minjie He, Yongzhang Su, Hongfei Li, Xuhui Feng, Na Xie, Jiaxin Huang, and Jian Peng. 2025. "Effects of Tool Rotational Speed on the Microstructure and Properties of Friction Stir Welded AZ61 Magnesium Alloy Joints" Metals 15, no. 10: 1128. https://doi.org/10.3390/met15101128

APA Style

Jin, X., He, M., Su, Y., Li, H., Feng, X., Xie, N., Huang, J., & Peng, J. (2025). Effects of Tool Rotational Speed on the Microstructure and Properties of Friction Stir Welded AZ61 Magnesium Alloy Joints. Metals, 15(10), 1128. https://doi.org/10.3390/met15101128

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