Contrasting Magnesium and Zinc Additions in AA6061 Aluminum Alloy: Microstructural and Mechanical Performance via Friction Stir Processing

Mustafa Sh. Aljanabi *

Department of Mechanical, College of Engineering, Tikrit University, Salah Aldin, Tikrit, Iraq.
* Corresponding Author
ORCID Details
 
Research Article
International Journal of Scholarly Research in Engineering and Technology, 2026, 08(02), 001–011.
Article DOI: 10.56781/ijsret.2026.8.2.0025
Publication history: 
Received on 22 August 2026; revised on 04 October 2026; accepted on 06 October 2026
 
Abstract: 
The present study examines the comparative effects of magnesium (Mg) and zinc (Zn) additions on the microstructural and mechanical behavior of the AA6061-T6 aluminum alloy modified by friction stir processing (FSP). The elements were added in various amounts (1–5 wt.%), and their effects on grain refinement, precipitation behavior, tensile strength, hardness, and ductility were investigated. Adding magnesium produced a more refined structure, with the most potent effect at 3 wt.%, yielding the best ultimate tensile strength of roughly 194 MPa and the best hardness. For Zn, at 5 wt.% peak strength reached values around 230 MPa, representing an increase of 48% compared to the base alloy, with microhardness exceeding 130 HV. Zn is better than Mg for maximizing strength and hardness. But if you want a strength-ductility balance, which is what you need in something that must have toughness, then you want Mg. This analysis indicates that compositional optimization of AA6061 can change its properties and behavior via FSP.
 
Keywords: 
Metal matrix composite, Mg/Zn particle reinforcement, Friction stir processing, Microstructural, Microhardness
 
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Copyright © 2026 Author(s) retain the copyright of this article. This article is published under the terms of the Creative Commons Attribution Liscense 4.0