Comprehensive analysis of minimum grain size in pure aluminum using friction stir processing

Abstract A friction stir processing (FSP) technique has been developed for use with aluminum and magnesium alloys, with the goal of high-strain-rate processing. In this study, we treat the microstructures of aluminum samples, of three levels of purity, manipulating their grain sizes, making them finer, using FSP. Grain sizes decreased with an increase in the Zener–Hollomon parameter, at all purity levels. However, the recrystallized grain of FSP-ed ultra-high-purity (99.999%) aluminum was particularly large, compared to the grain sizes of lower-purity (99% and 99.99%) aluminum, when subjected to the same processing conditions. The grain size reached a certain minimum value at high-strain-rates of processing, which we report for each purity level herein.