Plates of continuously cast AA5083 were subjected to friction stir processing (FSP) by three overlapping plunge and traverses. The FSP used a threaded pin tool with a pin diameter of 3 mm, pin length of 3 mm and a shoulder diameter of 10 mm. The process was run at constant tool rotation and traverse speeds of 800 rpm and 76.2 mm min-1, respectively. The microstructure of the processed region was examined by optical microscopy and orientation imaging microscopy. FSP of the AA5083 reduced the average grain size from approximately 60 m in the base metal to 3-4 m in the processed zone. In addition, it created a homogeneous microstructure and, in particular, a refined and homogenous particle distribution without damage to the particles. Large tensile samples with gage sections of 1x3x8 mm were prepared by wire EDM for high-temperature tension testing. Tensile tests were carried out at 450C under different strain rates. The relationship between strain rate and elongation was established. A maximum superplastic elongation of ~550% was obtained at a strain rate of 3 x 10-3 s-1. The formation mechanism of refined grain structure and the superplastic characteristic of FSP material will be discussed in this paper
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