Effect of friction stir processing on corrosion resistance of aluminum–copper alloy gas tungsten arc welds

Gas tungsten arc welds in aluminum–copper alloy AA2219-T6 were friction stir processed (to a depth of about 2 mm from the weld top surface) for improving their corrosion resistance. Unprocessed and friction stir processed welds were comparatively evaluated for their microstructural characteristics and corrosion resistance. Friction stir processing was found to result in substantial microstructural refinement with fine, uniformly distributed CuAl2 intermetallic particles. Friction stir processing was also found to result in a more uniform copper distribution in the weld metal, leading to significant increase in weld corrosion resistance. This work demonstrates that friction stir processing is an effective strategy for overcoming corrosion problems in aluminum–copper alloy fusion welds.