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Progress in sustainable manufacturing is a crucial element to minimise negative environmental impacts. The conventional fusion weld process used to join aluminium alloys resulted in coarse grain structure, inevitable defects, and severe joint softening. Friction stir processing (FSP) has the potential to modify the microstructure of materials in joint structure and improve the mechanical properties. In this investigation, the effect of friction stir post–processing was evaluated to study the microstructural characteristics and mechanical properties of GTAW (gas tungsten arc welding) welds in the aluminium 5052 alloy. During FSP, the grains’ dendritic microstructure was destroyed, and the dynamic recrystallisation resulted in a very fine and equiaxed grains structure in the fusion zone. The hardness of the friction-stir-processed welds significantly improved because of microstructure grain refinement. The processed joint demonstrated higher ultimate tensile and yield strength (~275 MPa and 221 MPa, respectively) and superior elongation (31.1%) compared to the unprocessed weld; at the same time, the mechanical strength (yield and ultimate tensile) is similar to that of the base metal.

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