The effects of friction stir processing (FSP) parameters such as rotational, traverse speeds and tool penetration depth on the formation of fine and defect free magnesium layers were investigated. The achieved microstructures were optically studied, and the microhardness profile of the optimised workpiece was measured. The results show that rotational and traverse speeds as well as their ratio play key roles in achieving a sound friction stir processed workpiece of pure Mg. In addition, at constant rotational and traverse speeds, when the penetration depth increases, the title angle must also increases in order to have a defect free workpiece. At optimum conditions, one pass FSP significantly refined the grain size from 3 mm in the as received magnesium to 14·6 μm in friction stir process layer. The microhardness of the fabricated layer reached to about 1·6 times that of the base metal.
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