ArticleScientific reports2026
Effect of post-weld friction stir processing on low-heat-input cold metal transfer (CMT) weld mechanical, microstructural and corrosion behaviors.
Article in Scientific reports, 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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Abstract
This study investigates the influence of post-weld friction stir processing (FSP) on 6-mm-thick AA6061 butt joints fabricated by low-heat-input cold metal transfer (CMT) welding using ER2219 filler. Weld integrity was evaluated using X-ray radiography, while microstructural features were examined by optical microscopy. Hardness was measured using Vickers micro-hardness testing, tensile properties were determined in accordance with ASTM E8, impact toughness was assessed by the Izod test, and corrosion behavior was characterized through potentiodynamic polarization in 3.5 wt.% NaCl solution. Friction stir processing produced a fine, equiaxed stir zone characterized by onion-ring flow patterns and clean, defect-free interfaces. The as-CMT joints exhibited an ultimate tensile strength of 216 MPa, a yield strength of 198 MPa, and an elongation of 12.6%. After applying friction stir processing (FSP), these values increased to 252 MPa, 215 MPa, and 23.8%, respectively, indicating substantial improvements in both strength and ductility. The Izod impact energy also increased markedly from 9.5 J in the as-CMT condition to 15.4 J after FSP, representing a 62% enhancement. The as-CMT sample displayed a lower corrosion current density than the CMT + FSP sample in 3.5 wt.% NaCl solution. Nevertheless, FSP resulted in notable improvements in strength, ductility, and hardness uniformity, whereas the as-CMT condition retained comparatively improved corrosion resistance, primarily due to its surface condition.
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