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Dissimilar friction stir welding of 2219-T8 and 2195-T8 aluminum alloys for fuel tanks: part II—effect of multi-pass repair welding

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Abstract

During the fabrication of fuel tanks by adopting friction stir welding (FSW), welding defects were almost unavoidable. The multi-pass repair FSW is the preferred repair welding technique for fuel tanks. However, the effect of muti-pass repair FSW on the microstructure and mechanical properties of dissimilar FSW 2219Al/2195Al joints lacks of investigation. In the present study, 2219Al-T8/2195Al-T8 plates were subjected to 1 ~ 3 passes repair FSW under 600 rpm–200 mm min−1 based on the initial joint 800 rpm–200 mm min−1 with placing 2219Al-T8 plates on the advancing side (AS). The results showed that, sound 1–3 passes repair FSW joints were obtained. The low hardness zone (LHZ) on the 2219Al-T8 side, characterized by the dissolution/coarsening of θ′ (Al2Cu) precipitates, showed the minimum hardness in the initial joint. Compared to the initial joint, the 1–3 passes repair FSW resulted in the moving of the location of LHZs far away from the weld center and coarser θ precipitates with higher density, and the hardness of the LHZ therefore decreased on the 2219Al-T8 side. The joint strength at − 196 °C was much higher than that at room temperature for both the initial and repair FSW joints. The 1 pass repair FSW weakened the joint strength at both the room temperature and − 196 °C. When increasing the repair pass from 1 to 2 and 3, the joint strength further decreased at room temperature but was unchanged at − 196 °C. The enlarged hardness gap between the nugget zone (NZ) and LHZ caused the narrowing of the necking zone at the LHZ on the 2219Al-T8 side for the multi-pass repair FSW joints. The material flow uniformity at the top of the NZ was improved by the 1 ~ 3 passes repair FSW, making the up bending failure location changing from the “S” line for the initial joint to the HAZ on the 2195Al-T8 side for the repair FSW joints.

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Data availability

The data that support the findings of this study are available from the corresponding author upon reasonable request.

Abbreviations

FSW:

Friction stir welding

BM:

Base material

NZ:

Nugget zone

TMAZ:

Thermal–mechanically affected zone

HAZ:

Heat affected zone

SDZ:

Shoulder driven zone

PDZ:

Pin driven zone

LHZ:

Low hardness zone

DIC:

Digital image correlation

TEM:

Transmission electron microscopy

SEM:

Scanning electron microscopy

YS:

Yield strength

UTS:

Ultimate tensile strength

EL:

Elongation

AS:

Advancing side

RS:

Retreating side

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Acknowledgements

This research is financially supported by (a) National Natural Science Foundation of China (No. 52275392); (b) the Youth Innovation Promotion Association of the Chinese Academy of Sciences (No. Y2021061); (c) Liaoning Province Excellent Youth Foundation (No. 2021-YQ-01); (d) Natural Science Foundation of Liaoning Province (No. 2021-MS-011); (e) Joint Funds of the National Natural Science Foundation of China (U21B6004); (f) Science & Technology of Heilongjiang Province's “Hundred, Thousand and Ten Thousand” project, (2020ZX03A03); and (g) the Bintech-IMR R&D Program (GYYJSBU-2022-002).

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Authors and Affiliations

  1. Shi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Science, Shenyang, 110016, China

    Zhenlin Wang, Zhen Zhang, Beibei. Wang, Peng Xue, Dingrui Ni, Fengchao Liu, Bolv Xiao & Zongyi Ma

  2. School of Materials Science and Engineering, University of Science and Technology of China, 72 Wenhua Road, Shenyang, 110016, China

    Zhenlin Wang, Zhen Zhang, Peng Xue, Dingrui Ni, Bolv Xiao & Zongyi Ma

  3. China Academy of Launch Vehicle Technology, Beijing, 100076, China

    Wenli Zhu, Feifan Wang & Weidong Zheng

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Contributions

ZLW was involved in the experimental operation, data analysis and writing original draft. WLZ contributed to the resources, conception and design of this study. ZZ was involved in the experiment design, analysis, project administration, funding acquisition and writing original draft. BBW contributed to the experimental operation and data analysis. PX contributed to the funding acquisition, conception and design of this study. DRN contributed to the experimental conception, experimental design, supervision, writing and editing original draft. FCL contributed to the experimental conception and design. ZYM contributed to the oversight, writing and editing original draft. BLX contributed to the conception and design of this study. FFW and WDZ contributed to the resources and investigation.

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Correspondence to Zhen Zhang or Dingrui Ni.

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Wang, Z., Zhu, W., Zhang, Z. et al. Dissimilar friction stir welding of 2219-T8 and 2195-T8 aluminum alloys for fuel tanks: part II—effect of multi-pass repair welding. J Mater Sci 59, 9697–9713 (2024). https://doi.org/10.1007/s10853-023-09209-5

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