Influence of Dual Soaking Durations and Variable Tool Feed Rates on Tensile Behavior of Friction Stir Welded Aluminum 2219

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Abstract:

Conventional welding of lightweight metals like aluminium and magnesium alloys raises concerns about joint strength and ductility. Conversely, friction stir welding (FSW) improves both by bonding materials through plastic deformation. This study revealed a clear correlation between tool feed rates and the mechanical performance of the joints. At lower feed rates, controlled plastic flow resulted in robust joint formation, enhancing both Ultimate tensile strength and Yield strength. Conversely, escalating the feed rate compromised joint strength due to imperfect joints and inadequate plastic flow. Artificial aging was found to play a pivotal role in enhancing the mechanical properties of FSW joints. Higher feed rates, despite initially leading to reduced ductility, showed improvements in yield strength following aging, primarily attributed to the reduction of flaws and defects within the joints. Artificial aging contributed to elevated yield strength values through grain boundary sizing and precipitate formation. However, it's important to note that the improvement in strength was not uniform across all feed rates, indicating that the influence of post-aging treatment was more pronounced for joints produced at feed rates other than 450 mm/min. Ductility experienced a significant decline (almost 50%) after artificial aging, especially for joints formed at higher feed rates, highlighting the trade-off between strength and ductility. Findings aid FSW optimization, designing joints with desired mechanical traits for applications valuing strength, ductility, and aging effects.

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Materials Science Forum (Volume 1164)

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15-25

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November 2025

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© 2025 Trans Tech Publications Ltd. All Rights Reserved

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