1) Mechanical Engineering Department, Indian Institute of Technology, Delhi-110016, India
2) Institut fuer Werkstoffwissenschaft, Technische Universitaet Dresden, Dresden-01069, Germany
3) Engineering Division, National Metallurgical Laboratory, Jamshedpur-831007, India
4) Institut fuer Sicherheitsforschung, Forschungszentrum Dresden-Rossendorf, Dresden-01328, Germany

The characterization of microstructure evolution in friction stir welded aluminum alloy was carried out by optical microscopy (OM) and transmission electron microscopy (TEM) and electron backscatter diffraction (EBSD). The weld nugget consisted of very fine equiaxed grains and experienced dissolution of nearly half of metastable precipitates into the matrix during welding. Thermomechanically affected zone (TMAZ) also experienced dissolution of precipitates but to a lesser extent whereas coarsening of precipitates was observed in heat affected zone (HAZ). Grain boundary misorientation measurements using EBSD indicated continuous dynamic recrystallization as the underlying mechanism for the fine equiaxed nugget grains. The yield and tensile strength of the weld decreased with comparison to base material. But due to the decrease of grain size and the dissolution of second phase precipitates, an increased Charpy energy value was observed in the weld nugget.