Investigation of microstructure and corrosion behavior of friction stir welded dissimilar joints AA5754-O to AA5052-O

Hassanein, Atef; Hassab-Allah, Ibrahim; Hussein Morsy, Hamada; AbuOkail, Mohamed Ibrahim

doi:10.21608/jesaun.2025.367641.1448

Investigation of microstructure and corrosion behavior of friction stir welded dissimilar joints AA5754-O to AA5052-O

JES. Journal of Engineering Sciences

Article 6, Volume 53, Issue 4, July and August 2025, Page 20-40 PDF (1.74 MB)

Document Type: Research Paper

DOI: 10.21608/jesaun.2025.367641.1448

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Authors

Atef Hassanein

¹; Ibrahim Hassab-Allah²; Hamada Hussein Morsy³; Mohamed Ibrahim AbuOkail⁴

¹Mining and Metallurgical Engineering Department, Faculty of Engineering ,Assiut University, Egypt.

²Professor of Manufacturing Engineering, Mechanical Engineering Department, Faculty of Engineering ,Assiut University, Egypt.

³Mining and Metallurgical Department - Faculty of Engineering ,Assiut University, Egypt.

⁴Manufacturing Engineering and Production Technology Department, Modern Academy for Engineering and Technology, Cairo, Egypt

Abstract

The durability of maritime structures is critically affected by harsh marine environments, where saltwater exposure accelerates corrosion and compromises structural integrity. This study investigates the influence of key friction stir welding (FSW) parameters on the microstructure and corrosion behavior of dissimilar aluminum alloys AA5754-O and AA5052-O, which are commonly used in marine applications. A systematic experimental design based on Taguchi’s L16 orthogonal array was employed, incorporating four process variables: rotational speed (710–2000 rpm), traverse speed (20–80 mm/min), tool tilt angle (1°–4°), and pin profile (triangular, taper threaded, cylindrical threaded). Electrochemical corrosion tests (potentiodynamic polarization), microstructural analyses (optical and SEM), and statistical tools (ANOVA) were used to evaluate weld integrity and identify optimal parameters. Results demonstrate that defect-free joints with enhanced corrosion resistance are achieved using a triangular pin profile at 1400 rpm, 40 mm/min, and 1° tilt angle. In contrast, welds produced with a tapered and cylindrical threaded tools under lower travel speed and higher tilt angle exhibited reduced corrosion resistance. This study provides practical insights into optimizing FSW conditions to fabricate durable, corrosion-resistant joints for marine environments, addressing a key gap in current dissimilar alloy welding research.

Keywords

Maritime structures; Corrosion; Dissimilar aluminum alloys; Microstructure; Optimization

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