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<p>During friction stir welding (FSW) of 2219 aluminum alloy components for large rocket tanks, mechanical strength degradation occurs due to the dissolution of strengthening precipitates within the welding region; although aging treatment is commonly used to restore joint strength, conventional furnace aging cannot be applied to large-scale, integrally welded aerospace structures. Although previous studies have demonstrated that electromagnetic induction heating pulsed aging (EIHPA) technology offers a novel technical approach to address the aforementioned issues, its effectiveness in enhancing the strength of welded joints in 2219 aluminum alloy has yet to be validated. In this work, EIHPA was applied to 2219 aluminum alloy FSW joints, and its effects on precipitate evolution, microstructural stability, and mechanical performance are systematically investigated. The results demonstrate that EIHPA effectively restores joint strength and hardness by promoting controlled reprecipitation of strengthening <i>θ</i>′ phases, yielding a tensile strength of 366&#xa0;MPa, equivalent to 83.2&#xa0;pct of the base metal strength; compared with conventional aging (CA), EIHPA significantly suppresses excessive coarsening of secondary phases, resulting in a more refined and stable precipitation microstructure. Fractography analysis further confirms the enhanced load-bearing capability of the nugget zone after EIHPA treatment. Overall, EIHPA offers superior mechanical recovery, higher processing efficiency, and strong adaptability for large-scale aerospace structures, demonstrating its considerable potential as a practical, robust, and scalable post-weld aging strategy for high-performance aluminum alloy assemblies.</p>

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Precipitation Evolution and Mechanical Response of 2219 Aluminum Alloy FSW Joints Under Electromagnetic Induction Heating Pulsed Aging

  • 期刊论文

  • 发表日期：

    2026年3月14日

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  • Huilin Miao,
  • Zhicheng Qiu,
  • Diqiu He,
  • Fei Xue,
  • Liyang Xiao,
  • Sheng Ding

摘要

During friction stir welding (FSW) of 2219 aluminum alloy components for large rocket tanks, mechanical strength degradation occurs due to the dissolution of strengthening precipitates within the welding region; although aging treatment is commonly used to restore joint strength, conventional furnace aging cannot be applied to large-scale, integrally welded aerospace structures. Although previous studies have demonstrated that electromagnetic induction heating pulsed aging (EIHPA) technology offers a novel technical approach to address the aforementioned issues, its effectiveness in enhancing the strength of welded joints in 2219 aluminum alloy has yet to be validated. In this work, EIHPA was applied to 2219 aluminum alloy FSW joints, and its effects on precipitate evolution, microstructural stability, and mechanical performance are systematically investigated. The results demonstrate that EIHPA effectively restores joint strength and hardness by promoting controlled reprecipitation of strengthening θ′ phases, yielding a tensile strength of 366 MPa, equivalent to 83.2 pct of the base metal strength; compared with conventional aging (CA), EIHPA significantly suppresses excessive coarsening of secondary phases, resulting in a more refined and stable precipitation microstructure. Fractography analysis further confirms the enhanced load-bearing capability of the nugget zone after EIHPA treatment. Overall, EIHPA offers superior mechanical recovery, higher processing efficiency, and strong adaptability for large-scale aerospace structures, demonstrating its considerable potential as a practical, robust, and scalable post-weld aging strategy for high-performance aluminum alloy assemblies.