| Summary: | In the present study, powder metallurgy processed unmilled AlMg5, milled AlMg5 and milled AlMg5-0.5 vol% Al2O3 nanocomposite have been successfully friction stir welded (FSW). The effect of friction stir welding on the evolution of weld microstructures; hardness and tensile properties were studied and discussed in detail. FSW of unmilled AlMg5 resulted in significant grain refinement and strain hardening in the nugget zone induced by the thermo-mechanical processing, thereby increasing the stir zone hardness and tensile strengths to 100 HV and 324 MPa when compared to 80 HV and 300 MPa of base metal, respectively. In contrast, the FSW of milled AlMg5 and milled AlMg5-0.5 vol% Al2O3 samples showed a reduction in UTS values to 375 MPa and 401 MPa in the stir zone compared to 401 MPa and 483 MPa of respective base metal values. Transmission electron microscopic (TEM) investigation of weld stir zones revealed the homogenous distribution of Al4C3 nanophases in milled AlMg5 and Al2O3 nanoparticles in milled AlMg5-0.5 vol% Al2O3 samples throughout the aluminium matrix. It was revealed that the pre-stored energy from the prior ball milling and hot pressing processes, higher deformation energy and grain boundary pinning effect due to the presence of reinforcement particles has resulted in a higher recrystallization tendency and retarded grain growth during FSW of milled samples. The welds prepared with milled AlMg5-0.5 vol% Al2O3 exhibited higher hardness and tensile strength in the stir zone when compared to all other conditions which was attributed to Hall Petch effect due to fine grain size and Orowan strengthening effect due to Al2O3 reinforcements. © 2016 Elsevier B.V.
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