Dissimilar Friction Stir Welding of Al and Ti: Elucidation of Microstructural Evolution, Material Flow, and Spring-Based Tensile Fracture Behavior

Welding aluminum (Al) to titanium (Ti) is particularly challenging because of the large differences in their melting points and the tendency to form cavities and brittle intermetallic compounds. Such issues can be mitigated in friction stir welding (FSW) by understanding the underlying mechanisms of microstructural evolution and tensile fracture behavior. In the present study, FSW was carried out on commercially pure Al and commercially pure Ti. X-ray micro-computed tomography results show that the distribution of Ti fragments depends on their morphology, with fine particles (volume 103–104 µm3) being distributed homogeneously, while large flakes (107–109 µm3) are concentrated near the joint interface. A three-dimensional analysis of Ti fragment distribution was performed to clarify material flow and particle dispersion within the weld nugget. EDS (Energy-Dispersive Spectroscopy) and EPMA (Electron Probe Microanalysis) composition mapping confirmed the formation of AlTi and Al3Ti intermetallic phases, with Al3Ti as the dominant phase (consistent with its lower Gibbs free energy of formation). Because Al is the primary element in the matrix and undergoes the highest degree of deformation, its microstructural evolution in Al was examined using Electron Backscatter Diffraction (EBSD). Grain refinement in Al was attributed to continuous dynamic recrystallization (CDRX). Mechanical mixing and intermetallic formation increased the hardness of the weld, while the tensile response corresponded to a joint efficiency of approximately 77%, alone with an 11% improvement in elongation over base Al. The study further establishes a correlation among Ti particle distribution, local microstructural evolution, and the tensile response of the joint. Fractographic analysis indicates a bimodal fracture mechanism, and failure occurred away from the joint interface, indicating a strong joint. To interpret this behavior, a spring-based model was proposed to relate the fracture location and tensile deformation to the spatial variation in microstructure across the welded zones. This approach provides a conceptual framework that is extendable to other dissimilar material systems with spatially varying microstructures.