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<p>Beryllium-aluminum (BeAl) alloys are widely used in the aerospace industry for their low density, high stiffness, and excellent thermal stability. However, the significant physical and metallurgical differences between Be and Al render conventional fusion welding methods ineffective for achieving high-quality joints. This study applied both conventional FSW and heat-assisted FSW to weld as-cast BeAl alloys. Comparative analysis reveals that the heat-assisted FSW process, which involves preheating both the base material and the backing plate, significantly enhances the plastic flowability of the material during welding and effectively prevents the formation of tunnel defects and surface cracks. The elevated temperature during welding promotes dynamic recrystallization, resulting in notable grain refinement in the weld nugget and an increase in microhardness to approximately 330 HV, about 2.3 times that of the base material. However, local microstructural inhomogeneity and microcracks within the Be particles still reduce the tensile strength of the joint to some extent. This study demonstrates the promising potential of heat-assisted FSW for addressing the welding challenges of BeAl alloys and provides valuable insights for future process optimization.</p>

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Microstructure and mechanical properties of a preheating friction stir welded beryllium aluminum casting alloy

  • 期刊论文

  • 发表日期：

    2025年9月25日

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  • Zuoyong Dou,
  • Shenghe Li,
  • Yawen Zhao,
  • Chengchen Dai,
  • Chao Lu,
  • Jianjun He,
  • Yubin Li,
  • Shengquan Xia,
  • Qingdong Xu,
  • Xinggen Guo

摘要

Beryllium-aluminum (BeAl) alloys are widely used in the aerospace industry for their low density, high stiffness, and excellent thermal stability. However, the significant physical and metallurgical differences between Be and Al render conventional fusion welding methods ineffective for achieving high-quality joints. This study applied both conventional FSW and heat-assisted FSW to weld as-cast BeAl alloys. Comparative analysis reveals that the heat-assisted FSW process, which involves preheating both the base material and the backing plate, significantly enhances the plastic flowability of the material during welding and effectively prevents the formation of tunnel defects and surface cracks. The elevated temperature during welding promotes dynamic recrystallization, resulting in notable grain refinement in the weld nugget and an increase in microhardness to approximately 330 HV, about 2.3 times that of the base material. However, local microstructural inhomogeneity and microcracks within the Be particles still reduce the tensile strength of the joint to some extent. This study demonstrates the promising potential of heat-assisted FSW for addressing the welding challenges of BeAl alloys and provides valuable insights for future process optimization.