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<p>AA2219 is a high-strength Al–Cu alloy widely used in aerospace and cryogenic structures, where weld integrity is critical for reliability. Forged components often exhibit coarse grains, which can influence weld quality and mechanical performance. This study evaluates the effect of the parent material’s large grain size on the microstructure and mechanical behavior of AA2219-T852 forgings welded using tungsten inert gas (TIG) and electron beam (EB) welding techniques. Forged plates with an average grain size of ~ 3000&#xa0;µm were welded and characterized using optical microscopy, scanning electron microscopy, and electron backscatter diffraction to analyze weld morphology, grain boundary evolution, and fusion zone structure. Mechanical performance was assessed through tensile testing and hardness mapping across the weld regions. The average UTS of EB- and TIG-welded joints in the longitudinal direction was 338&#xa0;MPa and 251&#xa0;MPa, respectively. EB welds exhibited higher tensile strength, improved joint efficiency, and refined equiaxed grains within the fusion zone due to the high energy density, deep penetration capability, minimal heat-affected zone formation, and rapid solidification associated with the process. The findings indicate that the coarse initial grain size of the AA2219 forging does not significantly influence the tensile properties of the weld joints. Overall, EB welding provides distinct advantages over TIG welding in producing sound, high-strength joints, demonstrating its suitability for aerospace structural applications.</p>

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Microstructural characterization and mechanical properties of electron beam and tungsten inert gas welded AA2219 forgings with large grain size

  • 期刊论文

  • 发表日期：

    2025年11月28日

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  • Pabitra Mohan Nayak,
  • Lagudu Yerrinaidu,
  • Rajiv Panda,
  • Rohit Kumar Gupta

摘要

AA2219 is a high-strength Al–Cu alloy widely used in aerospace and cryogenic structures, where weld integrity is critical for reliability. Forged components often exhibit coarse grains, which can influence weld quality and mechanical performance. This study evaluates the effect of the parent material’s large grain size on the microstructure and mechanical behavior of AA2219-T852 forgings welded using tungsten inert gas (TIG) and electron beam (EB) welding techniques. Forged plates with an average grain size of ~ 3000 µm were welded and characterized using optical microscopy, scanning electron microscopy, and electron backscatter diffraction to analyze weld morphology, grain boundary evolution, and fusion zone structure. Mechanical performance was assessed through tensile testing and hardness mapping across the weld regions. The average UTS of EB- and TIG-welded joints in the longitudinal direction was 338 MPa and 251 MPa, respectively. EB welds exhibited higher tensile strength, improved joint efficiency, and refined equiaxed grains within the fusion zone due to the high energy density, deep penetration capability, minimal heat-affected zone formation, and rapid solidification associated with the process. The findings indicate that the coarse initial grain size of the AA2219 forging does not significantly influence the tensile properties of the weld joints. Overall, EB welding provides distinct advantages over TIG welding in producing sound, high-strength joints, demonstrating its suitability for aerospace structural applications.