Advanced welding techniques for EN AW-1100 aluminum: microstructural and mechanical outcomes of self-support FSW

Abstract This study investigates the influence of Self-Support Friction Stir Welding (SSFSW) parameters on the microstructure and mechanical properties of EN AW-1100 aluminum alloy. The results reveal that varying rotational speeds (800–1800 RPM) and advance speeds (20–60 mm·min −1 ) significantly impact the grain structure, with grain sizes reduced from 20 μm to 12 μm, especially at lower advance speeds. Higher rotational speeds improved weld quality by minimizing defects like porosity, while increased advance speeds enhanced impact strength and joint homogeneity. Notably, the highest tensile strength (130 MPa) was observed in samples welded at 1000 RPM and 60 mm·min −1 , with a corresponding microhardness of 31 HV. The findings highlight SSFSW’s potential to produce robust, defect-free joints in commercially pure aluminum, suggesting its applicability for industrial applications where high-strength, reliable welds are critical. This research offers valuable insights into the optimal SSFSW parameters for EN AW-1100, addressing gaps in the current literature.