Machining Characteristics and Corrosion Behavior of Grain Refined AZ91 Mg Alloy Produced by Friction Stir Processing: Role of Tool Pin Profile

  • Hemendra Patle
  • Ravikumar Dumpala
  • B. Ratna Sunil
Technical Paper


In the present study, influence of friction stir processing (FSP) tool pin profile on the microstructure evolution, corrosion and machining characteristics of the AZ91 magnesium alloy was investigated. Three different pin profiles namely simple taper, threaded taper and square taper were selected and FSP was carried out at 1400 rpm and 25 mm/min tool travel speed. Microstructural observations indicated grain refinement from a starting grain size of 166.5–7.9, 22.1 and 4.08 µm for FSPed samples processed by simple taper, threaded taper and square taper pins, respectively. In all the FSPed samples, decreased amount of secondary phase (Mg17Al12) was observed compared with that of the unprocessed sample. From the X-ray diffraction analysis, it was observed that the square taper pin tool had induced higher texture effect compared with the other two FSP tools. From the electrochemical studies, the corrosion resistance of the sample processed with square taper pin tool was observed to be more in comparison to that of the other samples; which could be attributed to the texture effect and decreased fraction of secondary phase. Machining behavior assessed by conducting drilling experiments showed a significant influence of grain refinement on the cutting forces.


Magnesium Pin profile Machining Corrosion Texture Grain refinement 


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Copyright information

© The Indian Institute of Metals - IIM 2017

Authors and Affiliations

  • Hemendra Patle
    • 1
  • Ravikumar Dumpala
    • 1
  • B. Ratna Sunil
    • 2
  1. 1.Department of Mechanical EngineeringVisvesvaraya National Institute of TechnologyNagpurIndia
  2. 2.Department of Mechanical EngineeringRajiv Gandhi University of Knowledge Technologies (AP-IIIT)NuzvidIndia

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