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Friction stir processing is a solid-state process to modify microstructure and mechanical properties of sheet metals and as-cast materials. In this process, stirring action of the tool causes the material to intense plastic deformation that yields a dynamic recrystallization. In this study, the effect of friction stir processing (FSP) and process parameters on microstructure, mechanical properties, wear resistance, and corrosion behavior of AA5083-O has been investigated. Results show that FSP leads to finer and homogenized grain structure, as well as changes in hardness, corrosion resistance, and wear resistance of the material.

Friction stir welding has been successfully used to weld the dissimilar metals. A few investigations have been carried out on the friction stir lap welding of Al to Cu, but the basic issue of how the position of the metals would affect the joint strength is still not resolved. In the present study, the 7070 Al and the commercially pure copper are lap joined using friction stir lap welding technology. Two test cases are considered. The distinction refers to the position of Al with respect to Cu. Microstructural analyses are carried out to gain intermetallic compounds and some microcracks. The effect of position of materials on the heat generation is investigated and justified through the temperature measurements. Mechanical properties of each sample are characterized using both shear and hardness tests. The results reveal that the maximum fracture load of the joint is obtained when Al is placed on the top of Cu.

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