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Optimization of process parameters in friction stir welding of 2219 aluminum alloy thick plate

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Abstract

Optimal selection of friction stir welding (FSW) process parameters is critical for ensuring an even temperature distribution and high weld quality. This study ascertained the impact of process parameters on temperature distribution in the core area of friction stir welded 2219 aluminum alloy thick plate and determined the optimal combination (the range of rotational speed was estimated as 457.15–500.00 r/min, the welding speed was found within the range of 68.50–84.75 mm/min) of these parameters. The FSW process simulation model of 2219 aluminum alloy thick plate was established using DEFORM. The temperature field simulations of plunging, dwelling, welding, and withdrawal phases of FSW were also realized. Thermocouple temperature measurement experiments were performed to validate the model. The impact of welding process parameters on the core area’s maximum temperature and temperature difference was also investigated. The polynomial fitting method was used to establish a prediction model based on maximum and minimum temperatures of the FSW core area. The surface-fitting method was applied to draw the fitting surfaces of maximum and minimum temperatures, which intersected with the upper and inferior limit planes of reasonable welding temperature of 2219 aluminum alloy material, respectively. The intersection line was projected onto the plane with welding and rotational speeds as horizontal and vertical coordinates, respectively, and the optimized combination of welding process parameters was obtained.

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Funding

This research was supported by the National Key Research and Development Program of China (Grant No. 2019YFA0709003) and Natural Science Foundation of Liaoning Province of China(2023-MS-101). The financial contributions are gratefully acknowledged.

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Authors and Affiliations

  1. State Key Laboratory of High-performance Precision Manufacturing, Dalian University of Technology, 116024, Dalian, People’s Republic of China

    Xiaohong Lu, Yihan Luan, Jinhui Qiao, Banghua Yang & Weisong Zhang

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

    Steven Y. Liang

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  1. Xiaohong Lu
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  2. Yihan Luan
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  3. Jinhui Qiao
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Contributions

XL: conceptualization, supervision, methodology, funding acquisition, project administration. YL: software, investigation, formal analysis, data curation, validation, writing—review and editing. JQ: conceptualization, methodology, investigation, software, validation, writing—original draft. BY: formal analysis and investigation. WZ: formal analysis, data curation. SYL: resources.

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Correspondence to Xiaohong Lu.

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Lu, X., Luan, Y., Qiao, J. et al. Optimization of process parameters in friction stir welding of 2219 aluminum alloy thick plate. Int J Adv Manuf Technol 129, 4201–4215 (2023). https://doi.org/10.1007/s00170-023-12577-6

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