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Liquation in the partially melted zone (PMZ) is the critical weldability issue of cast AZ91 magnesium alloy. Friction stir processing (FSP) is used as a local pre-weld treatment to create a local liquation-resistant microstructure in cast AZ91 alloy during arc welding. The effects of tool rotational speed during pre-weld FSP on the liquation-related microstructural features (i.e. grain structure, size and volume fraction of eutectic β-Mg 17 Al 12 ) and the liquation characteristics of the fusion-welded AZ91 (i.e. PMZ size and grain boundary liquid film thickness) were investigated. The pre-weld FSP treatment of the cast AZ91 significantly improved the tensile strength and ductility of the welds mainly due to significant reduction in the thickness of the re-solidified eutectic β-Mg 17 Al 12  film in the PMZ.

Pre-weld friction stir processing enabling strong and ductile fusion welds on AZ91 magnesium alloy