Mechanical and Microstructural Properties of High-Speed Friction Stir Welding of AA 7020 Aluminum Alloy Using Multi-Pin Tool

High-speed friction stir welding (HSFSW) has emerged as a promising technique for improving the manufacturing efficiency of aluminum alloy structures by enabling faster welding while maintaining the quality of welded joints. This study investigates the mechanical properties and microstructural characteristics of AA 7020-T651 aluminum alloy joints welded using a novel multi-pin tool at high feed rates ranging from 2500 to 6000 mm/min under a constant rotational speed of 4000 rpm. Defect-free welds were successfully fabricated, as confirmed by metallographic analysis and micro-computed tomography (<i>µ</i>-CT). The multi-pin tool facilitated consistent material flow and heat distribution, which contributed to reliable joint formation across all feed rates. At the highest feed rate, the tensile strength reached 76% of the base material. A consistent softening in the nugget zone (NZ) was observed, and electron backscatter diffraction (EBSD) analysis showed a more than 70% grain size reduction in this zone, averaging ~3 µm, due to dynamic recrystallization. These findings underscore the suitability of HSFSW with multi-pin tools for high-speed industrial applications, offering enhanced productivity without compromising structural integrity.