Employing Cold Spray to Alter the Residual Stress Distribution of Workpieces: A Case Study on Fusion-Welded AA2219 Joint
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Employing Cold Spray to Alter the Residual Stress Distribution of Workpieces: A Case Study on Fusion-Welded AA2219 Joints W. Y. Li1 • Y. F. Zou1 • F. F. Wang2 • X. W. Yang1 • Y. X. Xu1 • K. W. Hu1 D. Y. Yan2
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Submitted: 29 October 2019 / in revised form: 13 March 2020 ASM International 2020
Abstract Eight-millimeter-thick high-strength AA2219 aluminum alloy plates were successfully welded by variable polarity tungsten inert gas welding, and the effect of cold spraying (CS) process on the residual stress, microstructure and mechanical properties of the welded joints were investigated. The CS experiment was performed under different driving gas temperatures and pressures and with different powder types. The microstructure of the as-welded joints and as-coated joints was analyzed by optical microscopy and scanning electron microscopy, while the residual stress was measured by the blind-holedrilling method. The results show that the CS process could significantly modify and re-distribute the residual stress of the welded joints. The maximum residual tensile stress of the welded joint has been significantly reduced by 111.9% and distributed more uniformly compared to the as-welded state. With the increase in gas temperature and/or pressure in CS, the residual tensile stress of joints was reduced, and even some compressive stress appeared. Among the powders of Cu, Al, and Ni, Cu particles have the best-improving effect. In addition, double-sided spraying This article is part of a special topical focus in the Journal of Thermal Spray Technology on Advanced Residual Stress Analysis in Thermal Spray and Cold Spray Processes. This issue was organized by Dr. Vladimir Luzin, Australian Centre for Neutron Scattering; Dr. Seiji Kuroda, National Institute of Materials Science; Dr. Shuo Yin, Trinity College Dublin; and Dr. Andrew Ang, Swinburne University of Technology. & W. Y. Li [email protected] 1
Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi’an 710072, China
2
Beijing Institute of Astronautical Systems Engineering, Beijing 100076, China
treatment can reduce the residual tensile stress of both sides more effectively. Besides, the grain size of the joint surface after CS was refined. Keywords AA2219 aluminum alloy cold spray residual stress variable polarity tungsten inert gas welding
Introduction AA2219 aluminum alloy is a high-strength Al-Cu alloy, which possesses a good combination of properties such as high strength-to-weight ratio, good fatigue and corrosion resistance and superior cryogenic properties (Ref 1, 2). It has been widely applied in the aerospace application, particularly in the construction of rocket fuel tanks (Ref 3, 4). Nowadays, tungsten inert gas (TIG) welding is one of the most popular welding methods to fabricate AA2219 aluminum alloy joints, which has advantages of good protection, stable arc, good weld appearance, simple operation, and relatively high weld quality. As an improved version of TIG, variable polarity tungste
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