Friction stir welding of high iron‐containing cast aluminum‐silicon‐magnesium alloys.

Abstract High iron‐containing cast aluminum‐silicon‐magnesium alloys have been developed for utilization recycled aluminum alloys. Iron‐containing intermetallic compounds (IMCs) are commonly considered as harmful to mechanical properties in the cast aluminum alloys containing Fe impurities. Friction stir welding (FSW) is applied to weld butt joint between cast aluminum‐silicon‐magnesium‐iron alloys plates with 1 wt.‐%, 2 wt.‐% and 4 wt.‐% Fe contents. Iron‐containing intermetallic compounds become finely fragmented and distributed in the aluminum matrix by friction stir welding. Friction stir welding clearly improves mechanical properties of the joints over the base materials. Fragmented intermetallic compounds in high iron‐containing aluminum‐silicon‐magnesium alloys can enhance tensile strength over the commercial A356 aluminum alloy.