Enhancing Formability of AA2219 Aluminum Alloy Friction Stir Welded Blanks with Preheating Treatment

The deformation behaviors of FSW blank are complicated due to the incompatibility of the mechanical property and microstructure for the weld and base material. In order to improve the formability of friction stir welded (FSW) blanks, the weld and base material in this paper were subjected to preheating treatments of 250, 300, 350, 400, and 450 °C, plus a solution treatment of 535 °C. The deformation behavior of the AA2219 FSW blank was characterized using uniaxial tension, microhardness test, hydro-bulging test and electron backscattered diffraction to determine the relationship of the deformation property and microstructure for the FSW blanks. Full strain fields of the tensile and bulging specimens were used to analyze the deformation uniformity of the weld and base material under uniaxial tension and biaxial tension stress states. With the limiting bulging height under various preheating temperatures, the formability behavior of the weld and base material was analyzed during the whole bulging process. The optimum preheating temperature can increase the formability and refrain from abnormal grain growth of the weld on the premise of maintaining the weld strength. The limiting bulging height of FSW blank is obviously improved by the lower preheating temperature from 300 to 350 °C. Additionally, the weld position has a significant impact on the deformation of the whole FSW blanks.