Microstructure and Mechanical Properties of Friction Stir Welded Aluminum 5083 Alloy Joints

Jawdat Al-Jarrah; Mohamed  H. Frihat; Maen Al-Rashdan; Firas Al Quran; Deya A. Al Qasy

doi:10.48084/etasr.14474

Authors

Jawdat Al-Jarrah Fire and Safety Engineering Department, Prince Al-Hussein Bin Abdullah II Academy for Civil Protection, Al-Balqa Applied University, Jordan
Mohamed H. Frihat Mechanical Engineering Department, Al-Huson University College, Al-Balqa Applied University, Jordan
Maen Al-Rashdan Mechanical Engineering Department, Al-Huson University College, Al-Balqa Applied University, Jordan
Firas Al Quran Mechanical Engineering Department, Al-Huson University College, Al-Balqa Applied University, Jordan
Deya A. Al Qasy Ministry of Education, Jordan

Volume: 16 | Issue: 3 | Pages: 35247-35254 | June 2026 | https://doi.org/10.48084/etasr.14474

Received: 2 September 2025 | Revised: 13 December 2025 and 18 March 2026 | Accepted: 19 March 2026 | Online: 6 June 2026

Corresponding author: Jawdat Al-Jarrah

Abstract

This research involved joining two 6-mm-thick 5083 aluminum alloy plates using Friction Stir Welding (FSW) and analyzing the mechanical properties of the resulting joints. Different joints were produced by varying the rotation speed from 400 rpm to 1,600 rpm in 200-rpm increments. Seven levels of welding speed were also utilized, ranging from 20 mm/min to 140 mm/min. The grain size and microhardness of the stir zone are influenced by the heat generated during welding. The grain size increased from 4.3 µm to 7.3 µm when the welding speed was 20 mm/min, while the microhardness decreased from 46 HV to 40 HV as the rotational speed increased from 400 rpm to 1600 rpm. A strong welded joint with an ultimate tensile strength of 210 MPa was produced at a rotational speed of 1200 rpm and a welding speed of 80 mm/min. The Rotation-per-Feed (RPF) ratio affects the mechanical properties of welded joints. RPF values between 12 and 18 were found to produce sound weldments with ultimate tensile strengths greater than 190 MPa. Additionally, it was observed that keeping the welding speed constant increases the ultimate tensile strength with rotational speed until it reaches an optimum value. Further increases in rotational speed led to a drop in the strength of the welded joint.

Keywords:

friction stir welding, aluminum alloy, ultimate tensile strength, welding

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