Microstructure and Fatigue Behavior of Friction Stir-welded Noncombustive Mg-9Al-Zn-Ca Magnesium Alloy

Microstructure and fatigue behavior of friction stir-welded noncombustive Mg-9Al-Zn-Ca magnesium alloy were investigated. The as-received hot-extruded material consisted of equiaxed α-Mg grains with β-Mg17Al12 and Al2Ca compounds distributed along the grain boundaries. Friction stir welding produced much refined α-Mg grains accompanied by the dissolution of the eutectic β-Mg17Al12 phase, while Al2Ca phase was dispersed homogenously into the Mg matrix. Friction stir welding produced slightly increased hardness and tensile strength in the defect-free welds compared with the base material due to microstructural refinement and uniform distribution of intermetallic compounds. The load-controlled uniaxial tensile high-cycle fatigue tests indicated that fatigue strength of 90 MPa was obtained for the friction stir-welded joint with fatigue crack initiated basically near the specimen’s surface and at the retreating side of the joint. Crack propagation was characterized by cleavage and fatigue striations.