Effect of Axial Ultrasonic on Microstructures and Properties of 2195 Aluminum Alloy Friction Stir Welded Joints

ZHAO Hongbo; JIN Zhengnan; LIU Xu; ZHANG Huijie; ZHAO Yunqiang

doi:10.3969/j.issn.1674-6457.2025.10.016

PDF(8783 KB)

Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (10) : 167-174. DOI: 10.3969/j.issn.1674-6457.2025.10.016

Advanced Manufacturing Technology and Equipment

Effect of Axial Ultrasonic on Microstructures and Properties of 2195 Aluminum Alloy Friction Stir Welded Joints

ZHAO Hongbo¹, JIN Zhengnan¹, LIU Xu², ZHANG Huijie^1,*, ZHAO Yunqiang³

Author information +

History +

Abstract

The aims to investigate the effects of axial ultrasonic-assisted friction stir welding (UAFSW) on the microstructure and properties of aluminum-lithium alloy welded joints and analyze the affecting mechanisms of ultrasonic on the microstructure evolution of weld and the enhancement of joint properties. The 2195-T8 aluminum alloy plates were treated through friction stir welding (FSW) and UAFSW. Optical microscopy, electron back scattered diffraction, and transmission electron microscopy were employed to analyze the weld formation, microstructures, and joint properties. The tensile strength and elongation at fracture of the UAFSW joints obtained at various rotation speed were consistently higher than those of the conventional FSW joints. The maximum tensile strength of UAFSW joint reached 74% of that of base metal. By analyzing the weak locations of the joints, i.e. the weld nugget zones, it was found that the width of the UAFSW weld nugget zone was narrower compared to that of FSW weld, while the width of the thermal-mechanically affected zone increased. After the ultrasonic energy was introduced, the grain size in the weld nugget zone was refined by 5.8%, with the proportion of recrystallized structure increasing by 10%. The dislocation exhibited more bending, and the density of T₁ phase was improved. The UAFSW process can significantly improve the mechanical properties of 2195 aluminum alloy joints. The improvement is attributed to the application of ultrasound, which not only further promotes dynamic recrystallization to refine the grains, but also increases the strain energy by increasing dislocation bending, thereby promoting the precipitation of T₁ phase. The findings establish a theoretical and technical foundation for the high-quality FSW manufacturing of aerospace aluminum-lithium alloy structures.

Key words

axial ultrasonic-assisted friction stir welding / aluminum-lithium alloy / microstructure / mechanical property / affecting mechanism

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

ZHAO Hongbo, JIN Zhengnan, LIU Xu, ZHANG Huijie, ZHAO Yunqiang. Effect of Axial Ultrasonic on Microstructures and Properties of 2195 Aluminum Alloy Friction Stir Welded Joints[J]. Journal of Netshape Forming Engineering. 2025, 17(10): 167-174 https://doi.org/10.3969/j.issn.1674-6457.2025.10.016

References

[1] LI S S, YUE X, LI Q Y, et al.Development and Applications of Aluminum Alloys for Aerospace Industry[J]. Journal of Materials Research and Technology, 2023, 27: 944-983.
[2] ABD EL-ATY A, XU Y, GUO X Z, et al. Strengthening Mechanisms, Deformation Behavior, and Anisotropic Mechanical Properties of Al-Li Alloys: A Review[J]. Journal of Advanced Research, 2018, 10: 49-67.
[3] MAHAKUR V K, GOUDA K, PATOWARI P K, et al.A Review on Advancement in Friction Stir Welding Considering the Tool and Material Parameters[J]. Arabian Journal for Science and Engineering, 2021, 46(8): 7681-7697.
[4] SONG K J, LIANG P C, FU X S, et al.Thickness Effect of 2195 Al-Li Alloy Friction Stir Weld Fracture Toughness[J]. Materials, 2024, 17(15): 3639.
[5] MENG X C, CHEN X, HAN Z L, et al.New Technique to Repair Keyhole of 2195 Al-Li Alloy Friction Stir Welding Joints[J]. Materials, 2024, 17(14): 3418.
[6] 刘钊, 孔德瑜, 邓磊, 等. 铝合金塑性成形粗晶现象的研究进展[J]. 精密成形工程, 2024, 16(3): 1-15.
LIU Z, KONG D Y, DENG L, et al.Advancements in Investigating Coarse Grain Phenomena in Aluminum Alloy Plastic Deformation[J]. Journal of Netshape Forming Engineering, 2024, 16(3): 1-15.
[7] LAI R L, HE D Q, LIU L C, et al.A Study of the Temperature Field during Ultrasonic-Assisted Friction-Stir Welding[J]. The International Journal of Advanced Manufacturing Technology, 2014, 73(1): 321-327.
[8] STRASS B, WAGNER G, EIFLER D. Realization of Al/Mg-Hybrid-Joints by Ultrasound Supported Friction Stir Welding[J]. Materials Science Forum, 2014, 783/ 784/785/786: 1814-1819.
[9] MENG X C, HUANG Y X, CAO J, et al.Recent Progress on Control Strategies for Inherent Issues in Friction Stir Welding[J]. Progress in Materials Science, 2021, 115: 100706.
[10] 贺地求, 彭建红, 杨坤玉, 等. 航空铝合金超声搅拌复合焊工艺及机理[J]. 中国有色金属学报, 2012, 22(10): 2743-2748.
HE D Q, PENG J H, YANG K Y, et al.Technology and Mechanism of Ultrasonic Stir Compound Welding of Aeronautical Aluminum Alloy[J]. The Chinese Journal of Nonferrous Metals, 2012, 22(10): 2743-2748.
[11] 武传松, 刘小超. 超声振动辅助搅拌摩擦焊的研究进展[J]. 焊接, 2013(4): 3-8.
WU C S, LIU X C.Research Progress and Trends in Ultrasound Vibration Assisted Friction Stir Welding[J]. Welding & Joining, 2013(4): 3-8.
[12] ELISEEV A A, FORTUNA S V, KALASHNIKOVA T A, et al.Structural Phase Evolution in Ultrasonic-Assisted Friction Stir Welded 2195 Aluminum Alloy Joints[J]. Russian Physics Journal, 2017, 60(6): 1022-1026.
[13] HU Y Y, LIU H J, FUJII H.Improving the Mechanical Properties of 2219-T6 Aluminum Alloy Joints by Ultrasonic Vibrations during Friction Stir Welding[J]. Journal of Materials Processing Technology, 2019, 271: 75-84.
[14] TARASOV S Y, RUBTSOV V Y, KOLUBAEV E A, et al.Ultrasonic-Assisted Friction Stir Welding on V95AT1 (7075) Aluminum Alloy[C]//Advanced Materials with Hierarchical Structure for New Technologies and Reliable Structures, Tomsk, Russia. AIP Publishing LLC, 2015: 020231.
[15] ZHAO W Z, ZHU Y L, LIU Z X, et al.Mechanism of Ultrasonic Effects on Thermal-Stress Field in Cu/Al-FSW Process[J]. International Journal of Mechanical Sciences, 2024, 270: 109101.
[16] ZHANG Q S, YAN A, CHEN K, et al.Effect of Tool Traverse Speed on Joint Line Remnant and Mechanical Properties of Friction Stir Welded 2195-T8 Al-Li Alloy Joints[J]. High Temperature Materials and Processes, 2023, 42(1): 20220265.
[17] SAHA R, BISWAS P.Current Status and Development of External Energy-Assisted Friction Stir Welding Processes: A Review[J]. Welding in the World, 2022, 66(3): 577-609.
[18] CHEN P, CHEN W H, CHEN J X, et al.Effect of Base Material Temper Condition on Precipitate Evolution and Mechanical Properties of 2195 AlLi Alloy Friction Stir Welding Joints[J]. Materials Characterization, 2024, 209: 113712.
[19] LI S, HOU X T, YAN D J, et al.Research Progress on the Microstructure, Mechanical Properties and Corrosion Resistance of Friction Stir Welded of Al-Li Alloy Joints[J]. Materials Today Communications, 2024, 39: 109194.
[20] GE F Y, LIU S, ZHANG X, et al.Effect of Grain Orientation on Microstructure and Mechanical Properties of FeCoCrNi High-Entropy Alloy Produced via Laser Melting Deposition[J]. Materials, 2023, 16(17): 5963.
[21] AGUSTIANINGRUM M P, VERMA S K, PETSCHKE D, et al.Revisiting Precipitates in Al-Cu-Li Alloys: Experiments and First-Principles Calculations of Thermodynamic Stability of Al₂CuLi(T1) Precipitate[J]. Journal of Alloys and Compounds, 2024, 991: 174495.
[22] ZHAO X Y, LIU W S, XIAO D H, et al.A Critical Review: Crystal Structure, Evolution and Interaction Mechanism with Dislocations of Nano Precipitates in Al-Li Alloys[J]. Materials & Design, 2022, 217: 110629.
[23] YOSHIMURA R, KONNO T J, ABE E, et al.Transmission Electron Microscopy Study of the Evolution of Precipitates in Aged Al-Li-Cu Alloys: The θ' and T1 Phases[J]. Acta Materialia, 2003, 51(14): 4251-4266.
[24] LI G H, XIAO W, LI X W, et al.The Influence of Aging Precipitates on the Mechanical Properties of Al-Li Alloys and Microstructural Analysis[J]. Metals, 2024, 14(5): 506.
[25] 谢冰鑫, 黄亮, 徐佳辉, 等. 2195铝锂合金时效析出行为与强化机理[J]. 中国有色金属学报, 2022, 32(8): 2160-2172.
XIE B X, HUANG L, XU J H, et al.Aging Precipitation Behavior and Strengthening Mechanism of 2195 Al-Li Alloy[J]. The Chinese Journal of Nonferrous Metals, 2022, 32(8): 2160-2172.
[26] 杨德庄. 位错与金属强化机制[M]. 哈尔滨: 哈尔滨工业大学出版社, 1991: 42-46.
YANG D Z.Dislocations and Strengthening Mechanisms of Metals[M]. Harbin: Harbin Institute of Technology Press, 1991: 42-46.

Funding

National Natural Science Foundation of China (52171032); Hebei Natural Science Foundation (E2023501002); Fundamental Research Funds for the Central Universities (2024GFYD003); Innovation and Entrepreneurship Training Program for College Students in Northeastern University at Qinhuangdao (CX24705)