Effect of self-support friction stir welding on microstructure and microhardness of 6082-T6 aluminum alloy joint

• A novel method of self-support friction stir welding (SSFSW) was introduced.
• The grain structure and second phase particles of SSFSW joint was reported.
• The microstructural development was a strong function of the local thermo-mechanical cycle.
• The TMAZ was characterized by coarse equiaxed grains and dissolution of precipitates.

In this paper, 5-mm-thick 6082-T6 aluminum alloy was joined by means of self-support friction stir welding (SSFSW). Here we report the grain structure and second phase particles in various regions including the welding nugget zone (WNZ), thermo-mechanically affected zone (TMAZ), and heat affected zone (HAZ). In the upper part of the joint, microhardness in the TMAZ in proximity of the UWNZ was the highest (average 89.4 HV) due to the severe plastic deformation. The similar result was also found in the lower part of the SSFSW joint. The microstructural development in each region was a strong function of the local thermo-mechanical cycle experienced during welding. Some coarse equiaxed grains which were produced in incomplete dynamic recrystallization process and dissolution of some precipitates have been observed in TMAZ. The HAZ retained the same grain structure as the base material, however, the grain size decreased with increasing distance of the weld centerline.