Dissimilar friction stir welding of 2219-T8 and 2195-T8 aluminum alloys: part I—microstructure evolution and mechanical properties
Source abstract
Abstract
The need for 2219 aluminum alloy and 2195 Al–Li alloy dissimilar friction stir welding (FSW) arises as the conventional 2219Al alloy was gradually replaced by the novel 2195Al alloy in fabrication of fuel tanks. However, the systematic investigation about the effect of welding parameters and material positioning on the microstructure evolution and mechanical properties of dissimilar FSW 2219Al/2195Al joints is lacking. In the present study, 2219Al-T8/2195Al-T8 plates were subjected to FSW under rotation rates of 800–1200 rpm and welding speeds of 200–800 mm min−1 with placing 2219Al-T8 alloys on the advancing side (AS) and retreating side (RS), respectively. The results showed that sound FSW joints were obtained under all the welding conditions. Welding parameters and material positioning affected the joint strength and fracture failure behavior. The FSW thermal cycle resulted in low hardness zones (LHZs) on both the 2219Al-T8 and 2195Al-T8 sides. The LHZ on the 2219Al-T8 side, characterized by partial coarsening of θ′ (Al2Cu) precipitates and dissolution of the residual precipitates, showed the minimum hardness in the entire FSW joints. When 2219Al-T8 alloy was placed on the AS, the LHZ on the 2219Al-T8 side experienced higher peak temperature, and therefore more dissolution of θ′ than that on the RS, thereby obtaining higher tensile strength. The tensile strength of the FSW joints at room temperature and − 196 °C largely increased as the welding speed increased from 200 to 400 mm min−1. The FSW joints presented much higher tensile strength at − 196 °C than that at room temperature under the identical welding parameters and material position. The FSW joints fractured along the LHZ on the 2219Al-T8 side during tension. For the bending testing, the up and down bending failure angles were about 91–117° and 88–109°, respectively, with the weak zone appearing in “S” line or HAZ on the 2195Al-T8 side.
Source: expertdata · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Advanced Welding Techniques Analysis · Aluminum Alloys Composites Properties · Aluminum Alloy Microstructure Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (38)
Show source-provided references
1. Xu WF, Liu JH, Luan GH, Dong CL (2009) Temperature evolution, microstructure and mechanical properties of friction stir welded thick 2219-O aluminum alloy joints. Mater Des 30(6):1886–1893. https://doi.org/10.1016/j.matdes.2008.09.02110.1016/j.matdes.2008.09.021 ↗
2. Wang G, Zhao Y, Hao Y (2018) Friction stir welding of high strength aerospace aluminum alloy and application in rocket tank manufacturing. J Mater Sci Technol 34(1):73–91. https://doi.org/10.1016/j.jmst.2017.11.04110.1016/j.jmst.2017.11.041 ↗
3. Rietz WW Jr (2009) Friction-stir welding–heavy inclusions in Bi-metallic welds of Al 2219/2195. In: 8th international conference on trends in welding research, pp 385–390. https://doi.org/10.1361/cp2008twr38510.1361/cp2008twr385 ↗
4. Mishra RS, Ma ZY (2005) Friction stir welding and processing. Mater Sci Eng R 50(1–2):1–78. https://doi.org/10.1016/j.mser.2005.07.00110.1016/j.mser.2005.07.001 ↗
5. Chen GQ, Yin QX, Zhang G, Zhang BG (2020) Fusion–diffusion electron beam welding of aluminum–lithium alloy with Cu nano–coating. Mater Des 188:108439. https://doi.org/10.1016/j.matdes.2019.10843910.1016/j.matdes.2019.108439 ↗
6. Sharma C, Upadhyay V, Narwariya BS (2019) Tensile properties of dissimilar friction stir weld joints of Al–2024 and Al–7039 alloys. Mater. Res Express 6(2):026524. https://doi.org/10.1088/2053-1591/aaeca310.1088/2053-1591/aaeca3 ↗
7. Khodir SA, Shibayanagi T (2008) Friction stir welding of dissimilar AA2024 and AA7075 aluminum alloys. Mater Sci Eng B 148(1–3):82–87. https://doi.org/10.1016/j.mseb.2007.09.02410.1016/j.mseb.2007.09.024 ↗
8. Guo JF, Chen HC, Sun CN, Bi G, Sun Z, Wei J (2014) Friction stir welding of dissimilar materials between AA6061 and AA7075 Al alloys effects of process parameters. Mater Des 56:185–192. https://doi.org/10.1016/j.matdes.2013.10.08210.1016/j.matdes.2013.10.082 ↗
9. Daniolos NM, Pantelis DI (2017) Microstructural and mechanical properties of dissimilar friction stir welds between 6082–T6 and 7075–T651. Int J Adv Manuf Technol 88:2497–2505. https://doi.org/10.1007/s00170-016-8965-x10.1007/s00170-016-8965-x ↗
10. Cavaliere P, De Santis AF, Squillace A (2009) Effect of welding parameters on mechanical and microstructural properties of dissimilar AA6082–AA2024 joints produced by friction stir welding. Mater Des 30(3):609–616. https://doi.org/10.1016/j.matdes.2008.05.04410.1016/j.matdes.2008.05.044 ↗
11. Fang Z, Wang F, Yin YH, Dong FB, Xu C, Zhang R, Chen K, Shan AD (2017) Microstructure and properties of 2195/2219 dissimilar alloy by FSW. Rare Metal Mater Eng 46(7):2017–2021
12. Wang F, Fang Z, Xu C, Yin YH, Chen K (2015) Microstructure and mechanical properties of FSW joints between dissimilar high-strength aluminum alloys. J Aeronaut Mater 35(1):33–38
13. Agilan M, Phanikumar G, Sivakumar D (2022) Tensile behaviour and microstructure evolution in friction stir welded 2195–2219 dissimilar aluminium alloy joints. Weld World 66:227–237. https://doi.org/10.1007/s40194-021-01217-w10.1007/s40194-021-01217-w ↗
14. Liu FC, Ma ZY (2008) Influence of tool dimension and welding parameters on microstructure and mechanical properties of friction–stir–welded 6061–T651 aluminum alloy. Metall Mater Trans A 39:2378–2388. https://doi.org/10.1007/s11661-008-9586-210.1007/s11661-008-9586-2 ↗
15. Ma ZY, Feng AH, Chen DL, Shen J (2018) Recent advances in friction stir welding/processing of aluminum alloys: microstructural evolution and mechanical properties. Crit Rev Solid State 43(4):269–333. https://doi.org/10.1080/10408436.2017.135814510.1080/10408436.2017.1358145 ↗
16. Zhang Z, Xiao BL, Ma ZY (2012) Effect of welding parameters on microstructure and mechanical properties of friction stir welded 2219Al–T6 joints. J Mater Sci 47:4075–4086. https://doi.org/10.1016/j.matdes.2011.03.05810.1016/j.matdes.2011.03.058 ↗
17. Zhang Z, Xiao BL, Ma ZY (2015) Enhancing mechanical properties of friction stir welded 2219Al–T6 joints at high welding speed through water cooling and post-welding artificial ageing. Mater Character 106:255–265. https://doi.org/10.1016/j.matchar.2015.06.00310.1016/j.matchar.2015.06.003 ↗
18. Tao Y, Zhang Z, Yu BH, Xue P, Ni DR, Xiao BL, Ma ZY (2020) Friction stir welding of 2060–T8 Al Li alloy: Part I: microstructure evolution mechanism and mechanical properties. Mater Charact 168:110524. https://doi.org/10.1016/j.matchar.2020.11050710.1016/j.matchar.2020.110507 ↗
19. Zhang J, Feng XS, Gao JS, Huang H, Ma ZQ, Guo LJ (2018) Effects of welding parameters and post-heat treatment on mechanical properties of friction stir welded AA2195-T8 Al-Li alloy. J Mater Sci Technol 34(1):219–227. https://doi.org/10.1016/j.jmst.2017.11.03310.1016/j.jmst.2017.11.033 ↗
20. Shu B, Guo XM, Zhang CX (2010) Microstructures and properties of friction stir welded joint of 2195 Al-Li alloy. J Aeronaut Mater 30(4):12–15
21. Tao Y, Ni DR, Xiao BL, Ma ZY, Wu W, Zhang RX, Zeng YS (2017) Origin of unusual fracture in stirred zone for friction stir welded 2198–T8 Al-Li alloy joints. Mater Sci Eng A 693:1–13. https://doi.org/10.1016/j.msea.2017.03.07910.1016/j.msea.2017.03.079 ↗
22. Das U, Toppo V (2018) Bending strength evaluation of dissimilar friction stir welded AA6101–T6 and AA6351–T65 aluminum alloys butt joint. Mater Today: Proc 5(5):11556–11562. https://doi.org/10.1016/j.matpr.2018.02.12310.1016/j.matpr.2018.02.123 ↗
23. Kang J, Si MY, Wang JJ, Zhou L, Jiao XD, Wu AP (2023) Effect of friction stir repair welding on microstructure and corrosion properties of 2219–T8 Al alloy joints. Mater Character 196:112634. https://doi.org/10.1016/j.matchar.2022.11263410.1016/j.matchar.2022.112634 ↗
24. Bertrand R, Robe H, Texier D, Zedan Y, Feulvarch E, Bocher P (2019) Analysis of AA2XXX/AA7XXX friction stir welds. J Mater Process Technol 271:312–324. https://doi.org/10.1016/j.jmatprotec.2019.03.02710.1016/j.jmatprotec.2019.03.027 ↗
25. Zhang Z, Xiao BL, Ma ZY (2013) Effect of segregation of secondary phase particles and “S” line on tensile fracture behavior of friction stir welded 2024Al–T351 joints. Metall Mater Trans A 44:4081–4097. https://doi.org/10.1007/s11661-013-1778-810.1007/s11661-013-1778-8 ↗
26. Wang ZL, Zhang Z, Xue P, Ni DR, Ma ZY, Hao YF, Zhao YH, Wang GQ (2022) Defect formation, microstructure evolution, and mechanical properties of bobbin tool friction-stir welded 2219–T8 alloy. Mater Sci Eng A 832:142414. https://doi.org/10.1016/j.msea.2021.14241410.1016/j.msea.2021.142414 ↗
27. Lorimer GW (1978) Precipitation Processes in Solids. TMS-AIME, Warrendale, Pa 121–160.
28. Chen YC, Feng JC, Liu HJ (2009) Precipitate evolution in friction stir welding of 2219–T6 aluminum alloys. Mater Charact 60(6):476–481. https://doi.org/10.1016/j.matchar.2008.12.00210.1016/j.matchar.2008.12.002 ↗
29. Srinivasan PB, Arora KS, Dietzel W, Pandey S, Schaper MK (2010) Characterisation of microstructure, mechanical properties and corrosion behaviour of an AA2219 friction stir weldment. J Alloy Compd 492(1–2):631–637. https://doi.org/10.1016/j.jallcom.2009.11.19810.1016/j.jallcom.2009.11.198 ↗
30. Paglia CS, Buchheit RG (2006) Microstructure microchemistry and environmental cracking susceptibility of friction stir welded 2219–T87. Mater Sci Eng A 49:107–114. https://doi.org/10.1016/j.msea.2006.05.03610.1016/j.msea.2006.05.036 ↗
31. Genevois C, Deschamps A, Denquin A, Doisneau-cottignies B (2005) Quantitative investigation of precipitation and mechanical behaviour for AA2024 friction stir welds. Acta Mater 53(8):2447–2458. https://doi.org/10.1016/j.actamat.2005.02.00710.1016/j.actamat.2005.02.007 ↗
32. Zhang Z, Xiao BL, Ma ZY (2014) Hardness recovery mechanism in the heat-affected zone during long-term natural aging and its influence on the mechanical properties and fracture behavior of friction stir welded 2024Al-T351 joints. Acta Mater 73:227–239. https://doi.org/10.1016/j.actamat.2014.04.02110.1016/j.actamat.2014.04.021 ↗
33. Sato YS, Urata M, Kokawa H (2002) Parameters controlling microstructure and hardness during friction-stir welding of precipitation-hardenable aluminum alloy 6063. Metall Mater Trans A 33:625–635. https://doi.org/10.1007/s11661-002-0124-310.1007/s11661-002-0124-3 ↗
34. Zhou L, Li GH, Liu CL (2017) Microstructural characteristics and mechanical properties of Al–Mg–Si alloy self-reacting friction stir welded joints. Sci Technol Weld Joi 22:438–445. https://doi.org/10.1080/13621718.2016.125173310.1080/13621718.2016.1251733 ↗
35. Narayana GV (2006) Fracture behaviour of aluminum alloy AA 2219-T87 welded plates at room and cryo temperatures. Indian Institute of Technology Bombay
36. Masoumi Khalilabad M, Zedan Y, Texier D, Jahazi M, Bocher P (2022) Effect of heat treatments on microstructural and mechanical characteristics of dissimilar friction stir welded 2198/2024 aluminum alloys. J Adhes Sci Technol 36(3):221–239. https://doi.org/10.1080/01694243.2021.191786810.1080/01694243.2021.1917868 ↗
37. Sato YS, Takauchi H, Park SHC, Kokawa H (2005) Characteristics of the kissing-bond in friction stir welded Al alloy 1050. Mater Sci Eng A 405:333–338. https://doi.org/10.1016/j.msea.2005.06.00810.1016/j.msea.2005.06.008 ↗
38. Xu WF, Liu JH, Luan GH, Dong CL (2009) Microstructure and mechanical properties of friction stir welded joints in 2219–T6 aluminum alloy. Mater Des 30:3460–3467. https://doi.org/10.1016/j.matdes.2009.03.01810.1016/j.matdes.2009.03.018 ↗