Microstructure evolution and texture characterization, corrosion behavior and mechanical properties of dissimilar AA 5083-8011 FSW joints with modified weld edge geometry and Al 2 O 3 reinforcement

The current study examines the impact of edge geometry, material positioning and Al 2 O 3 nanoparticle reinforcement on the evolution of the microstructure, mechanical properties and corrosion behavior of dissimilar friction stir welded AA 5083-AA 8011 aluminum alloys. Two edge configurations, plain and zigzag, were employed with alternate advancing and retreating side placements. Electron backscattered diffraction (EBSD) analysis shows significant grain refinement in zigzag joints especially in the zigzag 1-Al 2 O 3 condition. This condition has the finer grain size and the highest high-angle grain boundary fraction due to intensified dynamic recrystallization and particle-stimulated nucleation. Texture analysis revealed that Zigzag configurations had reduced shear texture intensity promoting microstructural isotropy. The scanning electron microscope (SEM) showed improved precipitate fragmentation uniform redistribution and compositional homogeneity in zigzag joints. XRD revealed α-Al as the dominant phase with stable retention of Al 2 O 3 nanoparticles and controlled intermetallic formation. Zigzag 1-Al 2 O 3 joints had higher hardness (45 ± 5.9 HV) and tensile strength (199 MPa) due to grain refinement, Zener pinning and improved interfacial interlocking. Corrosion studies revealed enhanced electrochemical stability in zigzag configurations with Zigzag 1-Al 2 O 3 having the most noble corrosion potential (0.212 V). Post-corrosion SEM revealed minimal pitting in optimized joints.