Effect of Friction Stir Welding Parameters on Mechanical Properties and Formability of Pre-Hardened 2219 Aluminum Alloy.
Saved in:
| Title: | Effect of Friction Stir Welding Parameters on Mechanical Properties and Formability of Pre-Hardened 2219 Aluminum Alloy. |
|---|---|
| Authors: | Ye, Xiaoming1,2 (AUTHOR), Meng, Xianlong1,2 (AUTHOR), Pang, Qiu3 (AUTHOR) pangqiu@wdu.edu.cn, Zhang, Sujia4 (AUTHOR) |
| Source: | Materials (1996-1944). May2026, Vol. 19 Issue 9, p1855. 19p. |
| Subjects: | Friction stir welding, Aluminum alloys, Aerospace technology, Ductility, Mechanical behavior of materials, Residual stresses, Microstructure |
| Abstract: | Highlights: Forward speed is the dominant parameter affecting mechanical properties of PH welded sheets. The excellent strength–ductility synergy in the PH welded sheets was attributed to a unique microstructural mechanism: the cooperative precipitation of θ″ and θ′ phases effectively hindered dislocation motion, while a high geometric compatibility factor (m′ > 0.7) promoted the activation of multiple slip systems and dislocation rearrangement. This study elucidates the microstructural mechanisms underlying the synergistic improvement in both strength and ductility of PH welded sheets under a process that combines FSW and PHF techniques. Offers critical guidelines for optimizing FSW parameters (specifically forward speed) to maximize the mechanical performance of PH alloys. In this study, the effects of friction stir welding (FSW) parameters on the mechanical properties and formability of pre-hardened (PH) 2219 aluminum alloy welds were systematically investigated through tensile testing and Erichsen tests. Energy dispersive spectrometry (EDS), electron back scatter diffraction (EBSD), and a transmission electron microscope (TEM) were employed to characterize the microstructure of the PH alloy weld joints, revealing the strength–ductility synergy mechanism of the PH welded sheets. Experimental results indicated that with respect to mechanical properties, when the welding rotational speed was fixed at 1000 rpm, increasing the forward speed from 50 mm/min to 150 mm/min reduced the ultimate tensile strength (UTS) by 6.3% and decreased the EL by 21.4%. When the forward speed was fixed at 50 mm/min, increasing the rotational speed from 500 rpm to 1500 rpm resulted in only a 0.4% variation in UTS and maintained a stable EL, demonstrating that forward speed is the dominant parameter affecting mechanical properties. In terms of formability, at a lower forward speed (50 mm/min), the Erichsen value exhibited a single-peak trend with increasing rotational speeds. At higher forward speeds (100 or 150 mm/min), the Erichsen value was insensitive to changes in rotational speed. When the rotational speed was fixed at 1500 rpm, increasing the forward speed from 50 mm/min to 150 mm/min reduced the Erichsen value by 21.3%. Microstructural strengthening mechanism: In the weld zone, the cooperative precipitation of the θ″ and θ′ phases effectively hindered dislocation motion. Simultaneously, the high geometric compatibility factor promoted the activation of multiple slip systems, and dislocation rearrangement subsequently led to the formation of sub-grain boundaries, thereby achieving strength–ductility cooperation. These findings provide theoretical support for the performance-driven welding process design of high-strength aluminum alloy components in aerospace applications. [ABSTRACT FROM AUTHOR] |
| Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
|
Full text is not displayed to guests.
Login for full access.
|
|
| Abstract: | Highlights: Forward speed is the dominant parameter affecting mechanical properties of PH welded sheets. The excellent strength–ductility synergy in the PH welded sheets was attributed to a unique microstructural mechanism: the cooperative precipitation of θ″ and θ′ phases effectively hindered dislocation motion, while a high geometric compatibility factor (m′ > 0.7) promoted the activation of multiple slip systems and dislocation rearrangement. This study elucidates the microstructural mechanisms underlying the synergistic improvement in both strength and ductility of PH welded sheets under a process that combines FSW and PHF techniques. Offers critical guidelines for optimizing FSW parameters (specifically forward speed) to maximize the mechanical performance of PH alloys. In this study, the effects of friction stir welding (FSW) parameters on the mechanical properties and formability of pre-hardened (PH) 2219 aluminum alloy welds were systematically investigated through tensile testing and Erichsen tests. Energy dispersive spectrometry (EDS), electron back scatter diffraction (EBSD), and a transmission electron microscope (TEM) were employed to characterize the microstructure of the PH alloy weld joints, revealing the strength–ductility synergy mechanism of the PH welded sheets. Experimental results indicated that with respect to mechanical properties, when the welding rotational speed was fixed at 1000 rpm, increasing the forward speed from 50 mm/min to 150 mm/min reduced the ultimate tensile strength (UTS) by 6.3% and decreased the EL by 21.4%. When the forward speed was fixed at 50 mm/min, increasing the rotational speed from 500 rpm to 1500 rpm resulted in only a 0.4% variation in UTS and maintained a stable EL, demonstrating that forward speed is the dominant parameter affecting mechanical properties. In terms of formability, at a lower forward speed (50 mm/min), the Erichsen value exhibited a single-peak trend with increasing rotational speeds. At higher forward speeds (100 or 150 mm/min), the Erichsen value was insensitive to changes in rotational speed. When the rotational speed was fixed at 1500 rpm, increasing the forward speed from 50 mm/min to 150 mm/min reduced the Erichsen value by 21.3%. Microstructural strengthening mechanism: In the weld zone, the cooperative precipitation of the θ″ and θ′ phases effectively hindered dislocation motion. Simultaneously, the high geometric compatibility factor promoted the activation of multiple slip systems, and dislocation rearrangement subsequently led to the formation of sub-grain boundaries, thereby achieving strength–ductility cooperation. These findings provide theoretical support for the performance-driven welding process design of high-strength aluminum alloy components in aerospace applications. [ABSTRACT FROM AUTHOR] |
|---|---|
| ISSN: | 19961944 |
| DOI: | 10.3390/ma19091855 |
