Effect of friction stir processing on the microstructure and hardness of an aluminum-zinc-magnesium-copper alloy with nickel additives

Abstract

The main object of this study is to investigate the effect of friction stir processing (FSP) on the microstructure and hardness of Al-Zn-Mg-Cu alloys that were produced via casting with the addition of 5 wt % nickel. Furthermore, a single-pass FSP with a rotational speed of 1500 rpm and a traveling speed of 40 mm/min was performed on the alloys. The FSP-treated cast alloys were homogenized, aged at 120°C for 24 h, retrogressed at 180°C for 30 min, and then re-aged at 120°C for 24 h. Microstructural evaluations via optical microscopy and scanning electron microscopy, as well as with energy dispersive X-ray spectroscopy were conducted. In addition, X-ray diffraction analysis was performed to detect the intermetallics and phases of the Al-Zn-Mg-Cu-Ni alloys. Before FSP, the microstructural observations indicated the presence of coarse Ni dispersed particles with a precipitate phase within the matrix. After FSP treatment, the grain refinement led to the uniform space distribution of Ni dispersed particles in the stir zone. The Vickers hardness values for the Al-Zn-Mg-Cu-Ni alloy increased after age tempering at T6 and retrogression and re-aging (RRA) treatment because of the increased precipitation and particles dispersity. The hardness of the Al-Zn-Mg-Cu-Ni alloy was enhanced after FSP and a series of heat treatments, especially the RRA process, because of the stirring action of the FSP tool, the grain refinement, the appearance of additional precipitates, and the refinement of dispersed Ni particles.