In this study, friction stir butt welding of Mg and Al alloys with applying Zn interlayer was performed. To obtain optimum condition, a combination of two travel and three rotation speeds were selected. Mg-Zn and Mg-Al-Zn IMCs, Al solid solution and residual Zn, were the most common phases in the stirred zone, which eliminated the formation of Al-Mg intermetallics. The maximum mechanical properties were achieved for the joint fabricated at 35 mm/min and 600 rpm, caused to 24% improvement in tensile strength and around 3 times enhancement of elongation compared with Zn free sample FSWed at the same conditions. The fracture micrographs were consistent with corresponding ductility results. Fracture surfaces of Zn-added samples presented a fine texture with a mixture of brittle and ductile fracture feature, which was different from the coarse cleavage plane and fully brittle fracture of the joint without Zn interlayer. 

Keywords: Friction stir welding, aluminum alloy, Magnesium alloy, Zn Interlayer, Microstructural characteristics, Mechanical properties.

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