This study examined effect of microstructure on the forming property in dissimilar thickness friction stir welds of 1mm- and 2mm-thick Al alloy 5052 sheets with three different cross-sectional features, i.e., weld without lazy S, weld with lazy S and weld with kissing-bond. The weld with kissing-bond cracked during root bending. The other welds containing the lazy S did not fail during bend testing. Microstructural analyses suggest that local distribution of oxide particles does not cause the cracking at the initial butt surface during root bending.
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