Microstructural evolution and mechanical properties of shear-spun 5052 aluminum alloy components under feed rate regulation

Abstract Cone-shaped 5,052 aluminum alloy components were fabricated via ambient-temperature shear spinning. This study systematically investigated the effects of varying feed rates on the microstructural evolution and mechanical performance of the spun parts. Electron backscatter diffraction (EBSD) analysis revealed that higher feed rates induced significant grain refinement: average grain size decreased by 37.3 %, from 9.33 μm to 5.85 μm, alongside the formation of a distinct <001>//RD texture. With increasing feed rate, dynamic recrystallization was slightly enhanced, while grain boundary misorientation, dislocation density, and low-angle grain boundary (LAGB) fraction were reduced. These microstructural changes indicate increased activation of crystallographic slip systems and improved plastic deformation capacity. Forming behavior showed the axial wall thickness of spun parts exhibited a V-shape (thicker at ends, thinner in the center), with end regions more susceptible to cracking due to steep strain gradients. Microhardness tests confirmed a significant post-spinning hardness increase, with improvements of 20.9 %, 24.0 %, and 22.8 % at respective feed rates relative to the initial unformed material.