Materials Science and Engineering A 472 (2008) 179186

Microstructure and tensile properties of friction stir welded

AZ31B magnesium alloy
N. Afrin a , D.L. Chen a, , X. Cao b , M. Jahazi b
a

Department of Mechanical and Industrial Engineering, Ryerson University, 350 Victoria Street, Toronto, Ontario M5B 2K3, Canada
b Aerospace Manufacturing Technology Centre, Institute for Aerospace Research, National Research Council Canada,
5145 Decelles Avenue, Montreal, Quebec H3T 2B2, Canada
Received 28 January 2007; received in revised form 5 March 2007; accepted 6 March 2007

Abstract
The microstructural change in AZ31B-H24 magnesium (Mg) alloy after friction stir welding (FSW) was examined. The effects of tool rotational
speed and welding speed on the microstructure and tensile properties were evaluated. The grain size was observed to increase after FSW, resulting
in a drop of microhardness across the welded region from about 70 HV in the base metal to about 50 HV at the center of the stir zone. The obtained
HallPetch type relationship showed a strong grain size dependence of the hardness. The aspect ratio and fractal dimension of the grains decreased
towards the center of the stir zone. The welding speed had a significant effect on the microstructure, with larger grains at a lower welding speed. The
yield strength and ultimate tensile strength increased with increasing welding speed due to a lower heat input. A lower rotational speed of 500 rpm
led to higher yield strength than a higher rotational speed of 1000 rpm. The friction stir welded joints were observed to fail mostly at the boundary
between the weld nugget and thermomechanically affected zone at the advancing side. Fracture surfaces showed a mixture of cleavage-like and
dimple-like characteristics.
Crown Copyright 2007 Published by Elsevier B.V. All rights reserved.
Keywords: Friction stir welding; Magnesium alloy; Microstructural characterization; Grain size; Aspect ratio; Fractal dimension; Microhardness; HallPetch
relationship; Tensile properties

1. Introduction
Friction stir welding (FSW) is a solid state metal joining technique which was developed and patented by The Weld Institute
of Cambridge, UK, in 1991 [1]. This technique is termed as
green technology by many researchers due to its energy efficiency and environment friendliness [2]. This joining technique
was first used to join aluminum and its alloys. Recently FSW is
being used to weld magnesium alloys and other alloys.
Structural applications of magnesium alloys are rapidly
increasing in automotive and aerospace equipment due to their
low density, and ease of castability. Joining of magnesium alloys
by conventional techniques is very difficult due to the several
problems such as, cracking, expulsion and void in the weld
zone [35]. FSW is capable of joining magnesium alloy without melting it and thus can eliminate problems related to the

Corresponding author. Tel.: +1 416 979 5000x6487; fax: +1 416 979 5265.
E-mail address: dchen@ryerson.ca (D.L. Chen).

solidification. As FSW does not requite any filler material in the

weld zone, the metallurgical problems associated with it can be
eliminated and good quality weld can be obtained.
Grain refinement and higher microhardness in the weld zone
of FSW AZ31 magnesium alloy were reported by Wang and
Wang [6], whereas Satoshi et al. [7] reported a lower hardness
and smaller grain size in the weld zone of AZ31 magnesium
alloy compared to the base metal. Nagasawa et al. [8] found
smaller grain size in the stir zone of hot rolled AZ31B plate
after friction stir welding with insignificant difference in the
hardness between the weld zone and the base metal. Separate
research carried out by Lee et al. [9] showed significant reduction in the weld hardness due to the evolution of bigger grain
size in the weld zone of FSW AZ31B-H24 hot rolled alloy.
Lee et al. [10] studied the effect of different friction stir welding
parameters on the tensile strength of extruded AZ31B-H24 magnesium alloy joints and reported that tensile strength decreases
with increasing welding speed, whereas Lim et al. [11] found
no significant effect of processing parameters on the tensile
strength of friction stir welded AZ31B-H24 alloy. Furthermore,

0921-5093/$ see front matter. Crown Copyright 2007 Published by Elsevier B.V. All rights reserved.
doi:10.1016/j.msea.2007.03.018

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investigations carried out by two separate researchers Wang and

Wang [6] and Pareek et al. [12] on AZ31B-H24 magnesium
alloy showed that the tensile strength increases with increasing
rotational speed. These studies showed significant effects of the
welding parameters (rotational speed and welding speed) on the
friction stir welded magnesium alloy. It is possible to produce
good quality joints with high strength using optimum welding
conditions. The purpose of this study is, therefore, to examine
the microstructural evolution, hardness and tensile properties of
friction stir welded joints of AZ31B-H24 magnesium alloy in
different welding conditions.
2. Experimental procedures
Friction stir butt welded joints of AZ31B-H24 magnesium
alloy, with a thickness of 4.95 mm and chemical composition of 2.53.5% Al, 0.71.3% Zn, 0.201.0% Mn and
the balance Mg, were selected in the present study. Friction stir welding was carried out using MTS-FSW machine
and in the direction perpendicular to the rolling direction. An
adjustable pin tool with a nominal pin diameter of 6.35 mm
and shoulder diameter of 19.05 mm was used in the present
investigation. Details of friction stir welding conditions are
shown in Table 1. Six different welding conditions were
applied to these samples. Welding speeds were varied from
1 to 4 mm/s, and rotational speeds were varied from 500 to
1000 rpm. Welding parameters of 500 rpm, 1 mm/s; 500 rpm,
2 mm/s; 750 rpm, 2 mm/s; 1000 rpm, 2 mm/s; 1000 rpm, 3 mm/s;
1000 rpm, 4 mm/s were indicated by samples I, II, III, IV, V and
VI, respectively.
Samples for microstructural characterization were taken perpendicular to the welding direction (i.e., parallel to the rolling
direction in this work). All samples were cut approximately
44 mm in length and were cold-mounted using Lecoset 7007
resin powder and liquid. The samples were then manually
ground and polished. The polished samples were etched using
5% nital to show general flow structure of the alloy. A standard
reagent made of 4.2 g picric acid, 10 ml acetic acid, 10 ml H2 O
and 70 ml ethanol (95% concentration) was used to reveal the
microstructure of the welded joints. Microscopic images were
taken by light microscope at a magnification of 400 and image
analyses were subsequently performed using Clemex software
to obtain the grain size, aspect ratio and fractal dimension of the
friction stir welded joints. Based on the fractal concept proposed
by Manderbrot [13], Manderbrot et al. [14], for irregular objects
Table 1
Welding parameters selected in the present study for the friction stir welding of
AZ31B-H24 magnesium alloy butt joints
Number

Rotational speed (rpm)

Welding speed (mm/s)

I
II
III
IV
V
VI

500
500
750
1000
1000
1000

1.0
2.0
2.0
2.0
3.0
4.0

Fig. 1. A typical example of perimeter (P) vs. area (A) of grains for sample VI
showing a linear variation of log(P) with log(A), where the slope represents a
half of the fractal dimension.

such as microstructures and fracture surfaces in materials the

following relationship holds among the perimeter (P), area (A)
and fractal dimension (D),
P 1/D A1/2 .
This equation can be rewritten as,
 
D
log A.
log P = constant +
2

(1)

(2)

It can be seen that D/2 is the slope of a straight line in a loglog

diagram of the perimeter versus area. A typical plot of the
grain perimeters (P) as a function of the grain areas (A) in the
double-log scales is shown in Fig. 1. A straight line can be seen
from the plot, where the fractal dimension is twice the slope
[1316].
A computerized Buehler microhardness testing machine was
used for the microindentation hardness tests where a load of
100 g and 15 s duration time were used. The test results were
recorded in the computer using a Hyper Terminal. Microindentation tests were performed along a path of 40 mm across
the sample with an interval of 0.5 mm between two successive
dents. The tests were carried out at different distances (e.g., 1
and 4 mm) from the bottom surface and at the top surface of the
samples, as shown in Fig. 2.
The samples for tensile tests were prepared according to the
ASTM E8 standard for sheet type material (i.e., 50 mm gage
length and 12.5 mm gauge width). Tensile tests were performed
at room temperature and at a strain rate of 6.0 104 s1 . Base
metal specimens and samples IV and VI were further tested
at a strain rate of 6.7 105 and 7.0 106 s1 to observe
the effect of strain rate. After tensile tests fracture surfaces
were examined using a scanning electron microscope (SEM)
equipped with an energy dispersive X-ray spectroscopy (EDS)
system.
3. Results and discussion
Fig. 2 shows an overall macroscopic cross sectional image
of the friction stir weld zone in sample IV of AZ31B-H24 alloy.

N. Afrin et al. / Materials Science and Engineering A 472 (2008) 179186

181

Fig. 2. A typical macroscopic image of the welded joint of sample IV after friction stir welding.

Fig. 3 shows typical optical micrographs of: (a) stir zone, (b)
thermomechanically affected zone (TMAZ), (c) heat-affected
(HAZ) and (d) base metal corresponding to the zones marked
in Fig. 2. The elongated grains in the base metal have become
equiaxed and recrystallized in the stir zone and transition zone
between thermomechanically affected zone and stir zone after
friction stir welding. The evolution of recrystallized grain structure in the stir zone is due to the severe plastic deformation and
frictional heat introduced by the rotating tool pin and its shoulder in the stir zone during welding [9,1719]. The grains in
the TMAZ in the present study have also become equiaxed and
recrystallized which is different from some magnesium alloys
[10] and most of the Al alloys [20] where the TMAZ was characterized by deformed and elongated grains. Fig. 4a shows the
variation of grain size across the FSW specimen at different
depths (at 1 and 4 mm from the bottom surface, and on the top
surface). The grain size of approximately 5 m of the base metal

became considerably bigger (8.59.3 m) in the center of the stir

zone after FSW. Slightly larger grains are observed on the top
surface compared to the bottom surface in the stir zone. The formation of larger grains in the stir zone was also reported by Lim
et al. [11] and Pareek et al. [12] for AZ31-H24 alloy. Similarly,
Chang et al. [19] observed a smaller grain size at the bottom
than at the top of friction stir processed AZ31 magnesium alloy
and the heat generated by the tool shoulder is considered to
be responsible for the formation of larger grains close to the
top surface. Fig. 4b refers to the variation of grain size across
the welded specimen having two different welding conditions
1000 rpm, 2 mm/s (sample IV) and 1000 rpm, 4 mm/s (sample
VI), respectively. The maximum grain size near the center of
the weld zone is slightly bigger in sample IV (about 10.2 m)
than in sample VI (about 9.3 m). The smaller grains produced
in the stir zone induced by the faster welding speed is attributed
to the relative lower heat input in the weld. Another reason for

Fig. 3. Optical microscope images of: (a) weld nugget, (b) thermomechanically affected zone (TMAZ), (c) heat affected zone (HAZ) and (d) base metal as indicated
in Fig. 2.

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Fig. 4. Grain size distribution across the weld (a) at different depths from the
bottom surface for sample VI (1000 rpm, 4 mm/s), (b) at a distance of 1 mm from
the bottom surface for sample VI (1000 rpm, 4 mm/s) and sample IV (1000 rpm,
2 mm/s).

the grain size reduction with increasing welding speed could be

the greater straining in the material which activates more strain
free nucleation sites as reported by Pareek et al. [12].
Fig. 5a shows typical profiles of aspect ratio of a specimen
where the aspect ratio is smaller in the stir zone due to the
equiaxed grains and it increases with increasing distance from
the weld centerline towards the base metal. Fig. 5b shows the
fractal dimension of grains in the AZ31B-H24 alloy across the
weld zone and base metal. Likewise, the fractal dimension close
to the center of the weld zone has smaller values than those close
to the base metal. This is due to the less irregularity in the stir
zone exhibited by the equiaxed grains. Fig. 6 shows a typical
hardness profile of a specimen (welding parameters 1000 rpm,
4 mm/s) across the weld zone at the top surface, 1 and 4 mm from
the bottom surface. The hardness profile shows a lower hardness
in the stir zone than in the base metal due to larger grain sizes
in the stir zone. Similar results were also observed in [9]. Vilaca
et al. [21] reported that if the ratio of the rotational speed (rpm)
to the welding speed (mm/min) becomes more than 4, it can be
considered as a hot welding condition and the resulting hardness exhibits a lower value between TMAZ and HAZ. Fig. 7
shows a comparison of hardness profiles between two samples
at 1 mm from the bottom surface and 4 mm from the bottom sur-

Fig. 5. (a) Aspect ratio and (b) fractal dimension as a function of the distance
from the center of stir zone for sample VI (1000 rpm, 4 mm/s) at different depths
from the bottom surface.

face, respectively. It is seen that sample VI with a higher welding

speed of 4 mm/s shows slightly higher hardness than sample IV
with 2 mm/s welding speed. The formation of smaller grain sizes
due to the lower heat input in sample VI (1000 rpm, 4 mm/s)
rendered slightly higher hardness in the weld zone compared to
sample IV (1000 rpm, 2 mm/s). The obtained hardness values
are plotted as a function of the reciprocal of the square root of

Fig. 6. Typical microhardness profile across the friction stir welded specimen
VI (1000 rpm, 4 mm/s) at different depths (top, 1 mm and 4 mm from the bottom
surface).

N. Afrin et al. / Materials Science and Engineering A 472 (2008) 179186

Fig. 7. A comparison of the hardness values between samples IV (1000 rpm,

2 mm/s) and VI (1000 rpm, 4 mm/s) at: (a) 1 mm from the bottom surface and
(b) 4 mm from the bottom surface.

the grain sizes in Fig. 8. The hardness values and grain sizes of
sample VI (1000 rpm, 4 mm/s) are taken at the center and both
sides of the weld nugget at a distance of 5, 10, 15 and 20 mm. It is
seen that the HallPetch type linear relationship is followed and
could be written as HV = 16.4 + 119.5d1/2 , where d is the grain
size. The relationship shows a strong grain size dependence of

Fig. 8. A typical plot of the HallPetch type relationship for the friction stir
welded sample VI (1000 rpm, 4 mm/s).

183

Fig. 9. Yield strength (YS) and ultimate tensile strength (UTS) of FSW AZ31BH24 alloy at: (a) different rotational speeds (rpm) and (b) different welding
speeds (mm/s).

the hardness in the FSWed AZ31B-H24 alloy. The grain boundaries thus become the main obstacle to the slip of dislocations
and the materials with a smaller grain size would have higher
hardness or strength as it would impose more restriction to the
dislocation movement.
Fig. 9 shows the tensile test results for specimens having: (a)
different rotational speeds and (b) different welding speeds. The
yield strength (YS) decreases with increasing rotational speed,
whereas the ultimate tensile strength (UTS) decreases when the
rotational speed changes from 500 to 750 rpm and then increases
form 750 rpm to 1000 rpm as seen in Fig. 9a. Fig. 9b shows both
YS and UTS increase with increasing welding speed. Specimens with a lower rotational speed (500 rpm) show a higher
yield strength than the specimens with a higher rotational speed
(1000 rpm) regardless of the welding speed. The highest UTS
of about 201 MPa in the present study was obtained for sample
VI (1000 rpm, 4 mm/s). An average elongation of about 2.5%
was observed for FSW joints, which is approximately 21% of
the elongation of the base metal. The base metal has also a
higher yield strength (about 208 MPa), ultimate tensile strength
(about 309 MPa) and elongation (12%) compared to those of
friction stir welded joints of AZ31B-H24 alloy, as indicated by
the dashed lines in Fig. 9a. The reason for such a decrease in
the tensile properties could be explained by the grain growth in
the stir zone and TMAZ, and the presence of significant amount

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N. Afrin et al. / Materials Science and Engineering A 472 (2008) 179186

Fig. 10. A comparison of the yield strength (YS) and ultimate tensile strength
(UTS) obtained in the present study with those reported in the literature.

of oxide layer in the boundary between the TMAZ and the stir
zone at AS, as reported by Lim et al. [11] and Gharacheh et al.
[22]. Another reason would be that magnesium alloys having
an hcp crystal structure found themselves responsible for this
reduction in the tensile properties due to the formation of new
crystallographic texture in the weld zone as reported by Park et
al. [17].
Fig. 10 presents a comparison of the tensile test results
obtained in the present study with those reported in the literature at varying welding speeds. It can be seen that the obtained
YS and UTS are in good agreement with the results reported
by other researchers [11,12]. Fig. 11 shows the tensile test
results of both base metal and friction stir welded joints under
conditions of 1000 rpm, 4 mm/s and 1000 rpm, 2 mm/s as a
function of the average strain rates. The change of the strain
rates seems to exhibit little or no effect on the YS and UTS
of AZ31B-H24 magnesium alloy and its FSWed joints. However, decreasing the tensile test strain rate from 6.0 104 to
6.7 105 s1 increases the elongation from 12 to16.4% for
the base metal, and from 2.3 to 3% for sample IV (1000 rpm,
2 mm/s), and slightly decreases the elongation from 3 to 2.8%
for sample VI (1000 rpm, 4 mm/s). Similar results on the elongation were observed when the strain rate was further decreased
to 7.0 106 s1 .
Fig. 12 shows a typical tensile fracture location of the friction stir welded joints of AZ31B-H24 alloy. Among 15 tensile

Fig. 11. Yield strength and ultimate tensile strength as a function of the strain
rate for the base metal and friction stir welded samples IV (1000 rpm, 2 mm/s)
and VI (1000 rpm, 4 mm/s) of AZ31B-H24 alloy.

samples tested, 14 of them failed at the boundary between the

stir zone and TMAZ at the advancing side. The failure of the
samples was basically 45 shear fracture, which could be due
to the formation of texture by the shear deformation resulted
from the rotation of the pin and tool shoulder in that region [12].
Some authors reported the fracture at the boundary between the
TMAZ and the stir zone due to the fact that the accumulation
of basal slip plane (0 0 0 1) having their normal parallel to the
transverse direction (TD) is maximum in that location leading
to the minimum Schmids factor [23,24]. Fracture locations are
observed to be about 58 mm from the weld centerline measured
at the top surface of the specimens. At a low rotational speed
of 500 rpm, failure occurs closer (56 mm from the weld centerline) to the weld nugget than at a higher rotational speed of
1000 rpm (68 mm from weld centerline). The lower rotational
speed creates smaller weld zone due to the lower heat input,
and the boundary between the TMAZ and the SZ (i.e., the fracture location in the present study) thus shifts closer to the weld
centerline [22].
Fig. 13 shows some typical SEM micrographs of fracture surfaces for: (a) the base metal, (b and c) the friction stir welded
joints. The base metal exhibits mainly features of elongated dimples together with some tear ridges, as shown in Fig. 13a. Both
dimple-like characteristics (Fig. 13b) and cleavage-like features
(Fig. 13c) can be seen in different areas on the fracture surfaces

Fig. 12. A macroscopic image showing typical fracture location of a friction stir welded specimen of AZ31B-H24 alloy.

N. Afrin et al. / Materials Science and Engineering A 472 (2008) 179186

185

Fig. 14. (a) An SEM micrograph of tensile fracture surface of a friction stir
welded specimen of AZ31B-H24 alloy and (b) EDS line scan profiles across the
particle showing the distribution of magnesium, oxygen and aluminum.

Fig. 13. Typical SEM micrographs of fracture surfaces of AZ31B-H24 alloy

after tensile testing: (a) base metal, (b and c) friction stir welded specimens III
(750 rpm, 2 mm/s) and VI (1000 rpm, 4 mm/s), respectively.

after FSW. Tensile fracture initiation could have started from

a cleavage area between the weld nugget and the TMAZ as
also reported by Lim et al. [11]. Fig. 14a shows an SEM image
taken from the tensile fracture surface of an FSW specimen
containing some particles. An EDS line scan analysis across the
particle reveals significant oxygen content as seen from Fig. 14b.
These oxide particles present on the fracture surface could be
the trapped oxide during friction stir welding and would be partially responsible for the reduction in the tensile strength and
elongation of the joints [10,11].

4. Conclusions
1. Microstructural examinations of AZ31B-H24 alloy after friction stir welding (FSW) revealed that the grains in the stir
zone and thermomechanically affected zone (TMAZ) exhibited recrystallization and growth. The grain shape became
equiaxed, giving rise to smaller values of both aspect ratio
and fractal dimension. Smaller grain sizes were observed in
the stir zone at a higher welding speed due to a lower heat
input.
2. Lower hardness values in the stir zone and the TMAZ were
observed. Faster welding speed produced slightly higher
hardness in the stir zone and the TMAZ. The obtained
HallPetch type relationship showed a strong grain size
dependence of the hardness of AZ31B-H24 alloy after FSW.

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N. Afrin et al. / Materials Science and Engineering A 472 (2008) 179186

3. The tensile test results showed that the yield strength and
ultimate tensile strength increased with increasing welding
speed due to the lower heat input in the weld region. A lower
rotational speed of 500 rpm gave rise to a higher yield strength
than a higher rotational speed of 1000 rpm.
4. The change in the strain rate from 6.0 104 to
6.7 105 s1 showed little or insignificant effect on the
yield strength and ultimate tensile strength of both base metal
and FSWed AZ31B-H24 alloy. However, the elongation of
the base metal increased from 12 to 16% when the strain rate
changed from 6 104 to 6.7 105 s1 .
5. The majority of the FSWed joints were observed to fail at the
boundary between the stir zone and the thermomechanically
affected zone (TMAZ) at the advancing side. The failure of
the tensile samples suggested a 45 shear fracture. The failure
in the TMAZ could be explained by the grain growth and the
presence of oxides on the fracture surface.
6. Fracture surfaces exhibited both cleavage-like and dimplelike fracture characteristics for the FSWed AZ31B-H24 alloy
after tensile tests.
Acknowledgements
The authors would like to thank the National Sciences and
Engineering Research Council (NSERC) of Canada for providing financial support. This investigation involves a part
of multi-national CanadaChinaUSA Collaborative Research
Project on the Magnesium Front End Research and Development
(MFERD). One of the authors (D.L. Chen) is also grateful for the
financial support by the Premiers Research Excellence Award
(PREA), Canada Foundation for Innovation (CFI) and Ryerson
Research Chair (RRC) program. The authors would also like to
thank Messrs. A. Machin, Q. Li, J. Amankrah and R. Churaman
for easy access in the laboratory of Ryerson University and their
assistance in the experiments during the study. Thanks are also
due to Mr. M. Guerin for the preparation of FSWed samples
using FSW system, and to Professor S.D. Bhole for his helpful
discussion.

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