Dynamic recrystallisation phenomena of commercial purity aluminium during friction welding

The microstructures of commercial purity aluminium near the friction weld interface were observed by transmission electron microscopy. Large plastic deformation of aluminium occurred near the weld interface and the microstructure of the aluminium was oriented from the centre to the periphery of the weld nugget. The aluminium grains were refined, and there were many recrystallised grains which were almost dislocation free. The refined grains, which were of size similar to 1 mum, formed very near the weld interface. The grain boundary was estimated to be a large angle tilt boundary. The refined grains were mainly formed by dynamic recrystallisation during the upset stage of the welding cycle. A large amount of shear strain and heat were introduced during the friction stage, and dynamic recrystallisation started during the upset stage. Grain growth occurred during air cooling after the upset stage. The grain size was larger in the central region than in the periphery, owing to the variation in temperature. The Vickers microhardness of aluminium near the weld interface increased owing to the microstructural refinement.