JMEPEG (2019) 28:1173–1179 ÓASM International

https://doi.org/10.1007/s11665-018-3844-2 1059-9495/$19.00

Effect of Friction Stir Processing on the Microstructure,

Damping Capacity, and Mechanical Properties of Al-Si
Alloy
H.J. Jiang, C.Y. Liu, Z.X. Yang, Y.P. Li, H.F. Huang, and F.C. Qin

(Submitted May 21, 2018; in revised form September 27, 2018; published online January 3, 2019)

Friction stir processing (FSP) was conducted on an Al-Si casting alloy. The Si phase and Al grains of an Al-
Si casting alloy were refined through FSP. Furthermore, FSP with high rotation rate led to the precipitation
of Mg and Si atoms and the formation of Mg2Si phase in the Al-Si alloy. Precipitation improved the low-
strain damping capacity but deteriorates high-strain damping capacity of the FSP sample at room tem-
perature. At low rotation rate, the FSP sample exhibited excellent high-temperature damping capacity
mainly because of its fine grain structure and the low density of its pinning points. The plastic instability of
the Al-Si alloy was eliminated by FSP because of the refinement of the Si phase. The increase in the strength
of each FSP sample was attributed to the increase in second-phase and boundary strengthening effects.
Thus, the mechanical properties and damping capacity of Al-Si were enhanced after FSP.

alloys exhibit a high room-temperature damping property at a

Keywords Al alloy, capacity, damping, mechanical properties,
microstructure
1. Introduction
Damping capacity is the ability of a material to dissipate
elastic strain energy during mechanical vibration or wave
propagation; it is gaining considerable attention in various
engineering fields (Ref 1-3). Al-Si casting alloys are widely
used because of their low density and cost, excellent mechan-
ical properties, and good thermal properties (Ref 4-6). How-
ever, the wide applications of such alloys require high
mechanical properties, and the damping capacity is limited by
their low damping (Ref 7).
In our previous studies, we showed that friction stir
processing (FSP) effectively improves the damping capacity
of wrought Al alloys, including 6082, 7075, 7055, and 7055-
0.25Sc Al alloys (Ref 8-11). According to the Granato–Lücke
model (dislocation damping mechanism), the room-temperature
damping capacity of metals can be improved by reducing their
dislocation pinning points (Ref 12). For the Al alloys, the solid
solution atoms and precipitates can act as mobile dislocation
pinning points during room-temperature vibration (Ref 13). The
temperature in the stirred zone of Al alloys during FSP usually
reaches 480 °C (Ref 14), which is sufficient to transform
coherent or semicoherent precipitates with fine sizes and high
densities into large incoherent phases with low densities (Ref 8-
11, 15-17). Thus, compared with Al alloys in the T6 state
(solution and peak-aging treatments), the dislocation pinning
effect of precipitates in Al alloy decreases, and the FSP Al
H.J. Jiang, C.Y. Liu, Z.X. Yang, Y.P. Li, H.F. Huang, and F.C. Qin,
Key Laboratory of New Processing Technology for Nonferrous Metal
and Materials, Ministry of Education, Guilin University of Technology,
Guilin 541004, China. Contact e-mail: lcy261@glut.edu.cn.
high-strain amplitude (Ref 8). Aside from the dislocation
damping mechanism, the grain boundary (GB) damping
mechanism is often used to explain the high-temperature
damping behaviors of metals (Ref 18). FSP samples are usually
characterized by high-temperature GB slipping capacity owing
to their equiaxed ultrafine-grained structures (Ref 19-21). Thus,
FSP significantly improves the high-temperature damping
properties of Al alloys. However, FSP deteriorates the strength
of wrought Al alloy because of the transformation or dissolu-
tion of the coherent and semicoherent phases in the Al matrix
during FSP (Ref 8-11, 15-17).
Unlike the main strengthening phases in 6xxx and 7xxx Al
alloys, the main strengthening phase in Al-Si casting alloys is
the large-sized Si phase (Ref 22). FSP can significantly break Si
particles to yield a uniformly distributed fine Si particles in the
Al matrix, thereby improving the mechanical properties of Al-
Si alloys (Ref 23-25) and possibly improving both the
mechanical properties and damping capacities of Al-Si casting
alloys.
In this study, we investigated the effects of FSP on the
microstructure, mechanical properties, and damping capacity of
Al-Si casting alloys at different rotation rates. The objective
was to fabricate Al-Si casting alloys with high strength and
ductility and excellent damping capacity.
2. Experimental
The base metal (BM) was a solid-solution-treated Al-Si
alloy (AA 4032 alloy). BM comprised of Al (85.2), Si (12.3),
Mg (1.1), Cu (0.5), Ni (0.5), Fe (0.3), and Zn (0.1) in wt.%.
FSP was conducted at a constant traverse speed of 100 mm
min1 and three tool rotation rates of 300, 800, and 1200 rpm,
which were denoted by FSP-300, FSP-800, and FSP-1200,
respectively. A tool with a concave shoulder of 10 mm diameter
and a taper threaded pin of 3.3 mm length was utilized.

Journal of Materials Engineering and Performance Volume 28(2) February 2019—1173

 The microstructures of the samples were examined by
optical microscopy (OM) and transmission electron microscopy
(TEM, JEOL-2010). TEM films were prepared by grinding the
alloy to a thickness of 30 lm, followed by ion milling.
Tensile tests were conducted using an Instron 3369-type
testing machine at a strain rate of 4 9 104 s1. Specimens for
tensile testing were machined parallel to the FSP direction.
Afterward, fracture surfaces were observed by scanning
electron microscopy (SEM, S-4800).
The internal friction (IF), which is the damping capacity of
the samples, was characterized using specimens with dimen-
sions of 1.2 mm 9 4 mm 9 25 mm. IF tests were performed
using a dynamic mechanical analyzer (Q800, TA) under single-
cantilever mode. Measurements were recorded at strain ampli-
tudes (e) of 5 9 105 to 1.7 9 101, frequencies (f) of 1 to 20
Hz, and temperatures (T) of 30 to 355 °C with a heating rate of
5 °C min1.
3. Results and Discussion
Figure 1 shows the OM micrographs of the BM and FSP
samples. A lath-shaped Si phase with several tens of microns in
length and several microns in width was observed in BM
(Fig. 1a). The Si particle has a hard brittle phase, the FSP
resulted in the significant destruction of the Si phase, and
Fig. 1 OM images of (a) BM and the (b) FSP-300, (c) FSP-800, and (d) FSP-1200 samples
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equiaxed-shaped Si particles with several microns in size were
uniformly distributed in the Al matrix of the FSP-300, FSP-
800, and FSP-1200 samples (Fig. 1b, c, and d).
Figure 2 shows the TEM micrographs of the BM and FSP
samples. The Al grain size in the BM was sufficiently large that
an entire grain cannot be observed in the field of vision, and a
high density of dislocations was observed in the Al matrix near
the Al/Si interface (Fig. 2a). The difference in the thermal
expansion between the Al matrix (23.86 9 106/K) and the Si
phase (15 9 106/K) resulted in the generation of dislocations
during solid solution treatment.
FSP is a severe plastic deformation process that promotes
recrystallization and grain refinement (Ref 16, 26). It also
refines Al grains contained in Al-Si BM. Moreover, second-
phase particles could hinder the motion of the Al matrix during
deformation and then increase the local strain and dislocation
density in the Al matrix surrounding these particles (Ref 27).
As such, the Si phase also promotes grain refinement of the
FSP-300 sample. Thus, ultrafine Al grains with size less than 1
lm were observed near the Si phase in the FSP-300 sample
(Fig. 2b).
The high rotation rate increased the heat input during FSP
(Ref 26), whereas the high temperature increase promoted the
coarsening of recrystallized Al grains and precipitation of the
Mg2Si phase in the FSP samples. Thus, the FSP-800 sample
exhibited higher grains size than the FSP-300 sample (Fig. 2c),
Journal of Materials Engineering and Performance
Fig. 2 TEM images of (a) BM and the (b) FSP-300, (c) FSP-800, and (d) FSP-1200 samples. (e) SAD pattern of particle ‘‘A’’ in (d)
and the precipitate phase was observed in the FSP-1200 sample
(Fig. 2d). In the FSP-1200 sample, particle ‘‘A’’ was in the Si
phase as identified by the selected area diffraction (SAD)
pattern (Fig. 2e). Thus, the high rotation rate further refined the
Si particles, some of which had sizes below 300 nm.
Figure 3 shows the room-temperature damping capacity of
BM and the FSP samples. The room-temperature IF values of
all the samples increased at increased strain amplitude. The
insets in Fig. 3 show that the room-temperature IF values of the
FSP-300 sample were similar to those of the BM during low-
Journal of Materials Engineering and Performance
and high-strain vibrations. Compared with BM and FSP-300
samples, the FSP samples with higher tool rotation rates
displayed higher IF values at low-strain amplitude and lower IF
values at high-strain amplitude.
According to the Granato–Lücke model, the movement of
dislocations can dissipate mechanical energy and improve the
damping capacity of a metal (Ref 12). Solute atoms acting as
‘‘weak pinning points’’ can impede the movement of disloca-
tion at a low-strain amplitude. The precipitation of Mg2Si
(Fig. 1d) provided a lower content of Mg and Si solute atoms in
Volume 28(2) February 2019—1175
Fig. 3 Strain amplitude-dependent damping capacity of the BM
and FSP samples
Fig. 4 TEM image of the FSP-1200 sample after high-strain
amplitude damping test at room temperature
the FSP-1200 sample than the BM and FSP samples with lower
tool rotation rates. Thus, the FSP-1200 sample presented high
IF values at low-strain amplitude.
With increasing strain amplitude, the dislocation segments
gradually were separated from the ‘‘weak pinning points’’ but
remained pinned to the ‘‘strong pinning points’’. The second
phase can act as ‘‘strong pinning points’’ in Al alloys during
room-temperature amplitude. Figure 4 shows the TEM image
of the FSP-1200 sample after a high-strain amplitude damping
test at room temperature. The dislocations in this sample were
pinned by the Mg2Si and fine Si phases. Thus, the high density
of the second phase (Fig. 1d) pinned the movement of the
dislocations of the FSP-1200 sample during high-strain ampli-
tude vibrations and decreased its high-strain IF values.
Figure 5 shows the high-temperature damping capacity of
the BM and FSP samples. The IF values of all samples
improved as the temperature increased. FSP improved the high-
temperature damping capacity of the Al-Si alloy, and the FSP-
300 sample exhibited higher IF values than the other three
samples at above 150 °C. Peaks were observed in the
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Fig. 5 Temperature-dependent damping capacity of BM and FSP
samples
temperature-dependent IF curves for the three FSP samples
but not in the curve of BM.
The peak of the temperature-dependent IF curves of Al
materials is associated with viscous sliding along the GBs (Ref
28-33). The fine equiaxed grains in the FSP samples provide
the excellent GB sliding capacities of these alloys at high
temperature (Ref 19-21). Thus, the peaks caused by GB
relaxation were observed in the temperature-dependent IF
curves of the FSP samples.
The GB and dislocation damping mechanisms were both
used to explain the high-temperature damping of metal (Ref
18).
During continuous heating, viscous flow converts mechan-
ical energy into thermal energy through the IF at GBs, thereby
improving the damping capacities of metals (Ref 34, 35). The
FSP samples presented a microstructure characterized by an
equiaxed fine grain structure with a random grain misorienta-
tion distribution. Such microstructure provides the excellent
GB sliding capacity and superplasticity at high temperature
(Ref 19-21). Thus, FSP samples exhibited higher high-temper-
ature IF values than the BM. The smaller grain size increased
the GB area of the FSP samples, dissipating more energy
during vibration at high temperature, according to the GB
damping mechanism (Ref 18, 36). The FSP-300 sample
exhibited finer grains than two other FSP samples because of
the low heat input during FSP. Furthermore, the refinement of
the Si particles and the precipitation of the Si and Mg atoms
were achieved through FSP when the tool had a high rotation
rate. Thus, the densities of the second phases, such as Si and
Mg2Si, in the FSP-300 sample were lower than those in other
two samples. These phases pinned the GB during vibration and
inhibited GB slipping. Consequently, the FSP-300 sample
displayed higher high-temperature IF values than the FSP-800
and FSP-1200 samples.
The number of point defects increases with increasing
temperature during vibration (Ref 37, 38). However, the
movement of these point defects was also pinned by the
pinning points during high-temperature vibration. The FSP-
1200 sample had a higher number of pinning points, such as Si
and Mg2Si, than the FSP-300 sample. Thus, the latter exhibits a
higher high-temperature IF value than the former according to
the dislocation damping mechanism.
Journal of Materials Engineering and Performance
Fig. 6 Frequency-dependent damping capacity of BM and FSP
samples
Figure 6 shows the effect of frequency on damping capacity
of BM and FSP samples at strain amplitudes of 6 9 102 and
temperature of 30 °C. The damping capacities of the BM and
FSP alloys were decreased with increasing frequency. Low
frequency stress can activate more pinned dislocations, thereby
increasing the numbers of mobile dislocations. Thus, higher
damping capacity was obtained in the samples during low-
frequency vibration.
Figure 7 shows the stress–strain curves of the BM and FSP
samples. BM showed an ultimate tensile strength (UTS) of less
than 120 MPa and a low ductility during the tensile process.
FSP improved both the strength and ductility of the BM. The
FSP-1200 sample exhibited the highest strength, and its UTS
reached 180 MPa. The FSP-300 sample presented the highest
ductility with 14% elongation, which is equal to the values of
commercial wrought Al alloys. Furthermore, work hardening
was identified in the stress–strain curves of the three FSP
samples.
Figure 8 shows the fracture surfaces of the BM and FSP-300
samples. The fracture surface of BM displayed a typical
cleavage fracture type, as evidenced by abundant brittle
cleavage planes (Fig. 8a). The FSP-300 sample exhibited a
ductile fracture with dimples and shear zones (Fig. 8b).
The Si phase of BM has a lath-like shape and a large size
(Fig. 1a) that provided preferential sites for crack nucleation
during tensile process, and the long Al/Si interfaces served as
the preferential crack propagation path, resulting in plastic
instability and poor ductility. In addition, the low ductility of
the BM made its strength low (Fig. 9).
FSP refined the Si phase, thereby increasing the densities of
the reinforced particles in the Al-Si alloy and eliminating
plastic instability of the alloy during tensile testing. The low
density of dislocations and fine Si particles increased the
capacity for accumulating new dislocations and enhanced the
work-hardening capacities of the FSP samples. Moreover, the
GB strengthening effect of the Al-Si alloy was increased by the
grain refinement of the Al matrix. Thus, FSP samples exhibited
a higher strength and ductility than BM. Considering the
increased density of fine Si and Mg2Si particles, the FSP-1200
sample exhibited higher strength and lower ductility than the
FSP samples with low tool rotation rates.
Journal of Materials Engineering and Performance
Fig. 7 Stress–strain curves of BM and FSP samples. The inset
shows the dimensions of the tensile specimens
The quality index Q was used to characterize the strength
and elongation (EL) of the Al-Si alloys. This value is a more
reliable parameter in engineering studies than elongation or
strength alone (Ref 39).
Q can be calculated using the following model described by
Drouzy (Ref 39):
Q ¼ UTS þ 150  logð%ELÞ ðEq 1Þ
Figure 8 shows the IF–Q relationship of the BM and FSP
samples. The three FSP samples showed evidently higher IF
and Q values than BM. Therefore, the Al-Si alloy presented
excellent damping capacity and mechanical properties after
FSP.
4. Conclusion
This work investigated the effects of FSP on the microstruc-
ture, damping capacity, and mechanical properties of Al-Si
alloys, which were summarized as follows:
1. The Si phase in the Al-Si alloy was significantly broken up
by FSP, and FSP reduced the density of dislocations and
promoted the grain refinement of Al-Si alloys. The high
rotation rate caused the precipitation of the Mg2Si phase.
2. The low content of solute atoms enhanced the low-strain
room-temperature IF values of the FSP-1200 sample,
whereas the high density of second phase decreased the
high-strain room-temperature IF values of this sample.
3. The high-temperature IF values of Al-Si alloys were sig-
nificantly enhanced by FSP, and the FSP-300 sample
exhibited the highest high-temperature IF values mainly
because of its fine grain structure and the low density of
pinning points.
4. The mechanical properties of Al-Si alloys were signifi-
cantly improved by FSP. The main strengthening mecha-
nisms of the FSP samples include the second-phase and
boundary strengthening. The precipitation of Mg2Si parti-
cles further reinforced the FSP-1200 sample.
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Fig. 8 SEM image of the fracture surfaces after tensile test: (a) BM and (b) FSP-300 samples
Fig. 9 IF–Q relationship of the BM and FSP samples
Acknowledgments
This work was funded by the National Natural Science
Foundation of China (No. 51601045), Guangxi ‘‘Bagui’’ Teams
for Innovation and Research, the Guangxi Natural Science
Foundation (No. 2016GXNSFDA380028), and the Guangxi
Science and Technology Major Project (No. GKAA17202007).
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