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National Key Laboratory of Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin 150001, PR China
National Key Laboratory of Advanced Welding Production Technology, Harbin Institute of Technology, Harbin 150001, PR China
Received 13 May 2005; received in revised form 29 November 2005; accepted 2 January 2006
Abstract
Friction stir welding (FSW) of 2219-O and 2219-T6 aluminum alloys was performed to investigate the effects of the base material conditions
on the FSW characteristics. The experimental results indicated that the base material condition has a significant effect on weld morphologies,
weld defects, and mechanical properties of joints. In the 2219-O welds, no discernible interface exists between the stir zone (SZ) and the thermalmechanically affected zone (TMAZ), and weld defects are liable to form in the lower part of the weld. In the 2219-T6 welds, there is visible
interface between the SZ and the TMAZ, and a weld nugget with an onion ring-like morphology clearly exists. The defects are liable to form in
the upper part of the weld. The strength efficiency of 2219-O joints is 100%, while that of 2219-T6 joints is only up to 82%. In addition, the two
types of joints have different fracture location characteristics.
2006 Elsevier B.V. All rights reserved.
Keywords: Friction stir welding; Aluminum alloy; Microstructure; Tensile property; Fracture location
1. Introduction
2. Experimental procedure
Friction stir welding (FSW) is a promising welding process and is being extensively studied because it can produce
high-quality joints of aluminum alloys [1,2]. A great number of
studies have focused on the effects of the welding parameters
on the FSW characteristics, such as microstructural evolution in
the joints [37], thermal cycle histories during welding [810],
residual stress distributions in the joints [11,12], material flow
behavior in the welds [1317], and mechanical properties of
the joints [1823]. Only a small number of studies have been
involved with the effects of the base material conditions on the
FSW behavior, especially the effects of heat treatment states
of the same types of aluminum alloys [24,25]. Studies on this
topic are important to reveal and comprehend the friction stir
weldability of aluminum alloys. In the present study, different
heat-treated-state aluminum alloys, 2219-O and 2219-T6, are
selected as the experimental materials for FSW. The emphasis
was placed on the morphologies, defects, tensile properties, and
fracture locations of the joints.
Corresponding author. Tel.: +86 451 86418146; fax: +86 451 86418146.
E-mail address: liuhj@hope.hit.edu.cn (H. Liu).
0921-5093/$ see front matter 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.msea.2006.01.029
22
Table 1
Chemical compositions and mechanical properties of 2219-O and 2219-T6 aluminum alloy plates
Base material condition
2219-O
2219-T6
Mechanical properties
Al
Cu
Mn
Fe
Ti
Zn
Si
Zr
Elongation (%)
Bal.
Bal.
6.8
6.8
0.32
0.32
0.23
0.23
0.06
0.06
0.08
0.08
0.04
0.04
0.49
0.49
0.2
0.2
159
416
17.5
15
Table 2
Welding tool size and welding parameters used in the experiments
Base material condition
2219-O
2219-T6
Tool size
Welding parameters
15
15
6
6
4.8
4.8
800
800
60500
60300
Fig. 1. Cross-sections of FSW joints welded at 200 mm min1 : (a) 2219-O joint and (b) 2219-T6 joint.
Fig. 2. Cross-sections of FSW joints: (a) 2219-O joint welded at 500 mm min1 and (b) 2219-T6 joint welded at 300 mm min1 .
23
Fig. 3. Mechanical property efficiencies of 2219-O and 2219-T6 joints: (a) TSE and (b) EE.
Fig. 4. Strain distributions in the joints: (a) 2219-O and (b) 2219-T6.
FSW process is similar to an extrusion process [26,27]. During each rotation of the tool, a thin-layer plasticized material
is pushed to the back of the tool [26]. The weld along welding
direction is characterized by the accumulation of multi-layer
plasticized material. Therefore, the cross-section of the weld
24
Fig. 5. Micro-hardness distributions in the joints: (a) 2219-O and (b) 2219-T6.
to fracture in the BM, while the one for the 2219-T6 joints
are prone to fracture in the HAZ on the RS. When the welding speed is greater than the critical value, the two types of
joints are all fractured in the weld on the AS.
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