Characterization of TIG and FSW weldings in cast ZE41A magnesium alloy

•Sound joints have been obtained in cast ZE41A Mg alloy by TIG and FSW processes.•Obtained joints satisfy the Aerospace Material Specifications AMS 4439F normative.•Some advantages can be obtained using FSW w.r.t. TIG process.•The longitudinal residual stresses induced by FSW follow an M-shaped distribution. The quality of the joints, in terms of surface aspect and material deposition, was verified by visual inspection, liquid penetrant and X-ray NDT. The chemical composition in the weld zone was estimated by spectrometric analysis, while microstructural aspects were inferred by conventional metallographic techniques. Tensile and hardness tests revealed the conformity of the joints to acceptance criteria specified by AMS 4439F normative. The longitudinal residual stresses induced by FSW, measured using the contour method, follow an M-shaped distribution with the absolute maximum equal to 109MPa in the advancing side of the weld. Obtained outcomes highlight the feasibility of the FSW process and some advantages achievable w.r.t. TIG process.