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Welding parameters optimization during plunging and dwelling phase of FSW 2219 aluminum alloy thick plate

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Abstract

The influence of welding parameters on temperature distribution during plunging and dwelling phase of friction stir welding (FSW) 2219 aluminum alloy thick plate has not been studied. Improper selection of welding parameters will result in uneven temperature distribution along with the thickness of the weldment, leading to welding defects and ultimately affecting the mechanical properties of the weldment. To achieve the prediction of temperature distribution and the optimization of welding parameters, a simulation process model of FSW 18-mm-thick 2219 aluminum alloy is established based on DEFORM. The validity of the simulation is verified by experiments. With the minimum temperature difference in the core area of the weldment as the target value and weldable temperature range of 2219 aluminum alloy as the constraint conditions, orthogonal experiments are conducted considering the rotational speed, the press amount, the tool tilt angle, the plunging traverse speed and the dwelling time. The results of variance analysis show that the rotational speed and the dwelling time are significant factors affecting the temperature field during the plunging and dwelling phase. Through single factor simulation, the welding parameters during the plunging and dwelling phase are optimized. This study guides the selection of welding parameters of the FSW 2219 aluminum alloy thick plate.

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Funding

The research was supported by the National Key Research and Development Program of China (grant no. 2019YFA0709003), Dalian Science and Technology Innovation Fund (grant no. 2020JJ26GX041), and the Fundamental Research Funds for the Central Universities (grant no. DUT20ZD204). The financial contributions are gratefully acknowledged.

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Authors and Affiliations

  1. Key Laboratory for Precision and Non-Traditional Machining Technology of Ministry of Education, Dalian University of Technology, 116024, Dalian, People’s Republic of China

    Xiaohong Lu, Jinhui Qiao & Junyu Qian

  2. Capital Aerospace Machinery Company, 100071, Beijing, People’s Republic of China

    Shixuan Sun

  3. The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA, 30332-0405, USA

    Steven Y. Liang

Authors
  1. Xiaohong Lu
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  2. Jinhui Qiao
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  3. Junyu Qian
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  4. Shixuan Sun
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  5. Steven Y. Liang
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Contributions

Xiaohong Lu: conceptualization, supervision, methodology, funding acquisition, project administration, writing—review, and editing. Jinhui Qiao: conceptualization, methodology, software, validation, writing—original draft, investigation, writing—review, and editing. Junyu Qian: formal analysis, data curation. Shixuan Sun: software, investigation, and formal analysis. Steven Y. Liang: supervision, methodology, and resources.

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Correspondence to Xiaohong Lu.

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Lu, X., Qiao, J., Qian, J. et al. Welding parameters optimization during plunging and dwelling phase of FSW 2219 aluminum alloy thick plate. Int J Adv Manuf Technol 120, 6163–6173 (2022). https://doi.org/10.1007/s00170-022-09098-z

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