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This paper presents the analysis of the friction stir-processed aluminium alloy 5083-H111 gas tungsten arc-welded and friction stir-welded joints. The comparative analysis was performed on the processed and unprocessed gas tungsten arc-welded and friction stir-welded joints of similar aluminium alloy 5083-H111. The results showed a clear distinction between the friction stir processed joints and unprocessed joints. There is a good correlation observed between the microstructural results and the tensile results. Ultrafine grain sizes of 4.62 μm and 7.177 μm were observed on the microstructure of the friction stir-processed friction stir-welded and gas tungsten arc-welded joints. The ultimate tensile strength for friction stir-welded and gas tungsten arc-welded before friction stir processing was 153.75 and 262.083 MPa, respectively. The ultimate tensile strength for friction stir processed friction stir-welded joint was 303.153 MPa and gas tungsten arc-welded joints one was 249.917 MPa. The microhardness values for the unprocessed friction stir-welded and gas tungsten arc-welded joints were both approximately 87 HV, while those of the friction stir-processed ones were 86.5 and 86 HV, respectively. The application of friction stir processing transformed the gas tungsten arc morphology from brittle to ductile dimples and reduced the ductile dimple size of the unprocessed friction stir-welded joints from the range of 4.90–38.33 μm to 3.35–15.59 μm.

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The submerged friction stir processing (SFSP) technique was employed on the prior friction stir welded (FSW) AA6082/AA8011 dissimilar aluminum alloy joints. The tap water with room temperature was kept at 40 mm depth throughout the processing. The AA6082 was kept at the advancing side during FSW and SFSP process and this was done to enhance the strength of the joint. The SFSP joints were studied comparatively with the FSW joints. The sampling position was also studied for both the FSW joint and SFSP joint. The employment of the submerged friction stir processing resulted in the microstructural grain size refinement. The tensile strength of the SFSP joint was found to be higher than that of AA8011 base metal but lower than that of AA6082 base metal. The tensile strength of the FSW joint was found to be lower than that of both base metals. There was a clear correlation between the tensile properties and the grain size refinement. The SFSP joint exhibited good microhardness properties compared to the FSW joint.