A quasi-in-situ EBSD study on abnormal grain growth in 2219 aluminum alloy friction stir welded joints during post-weld heat treatment

• A quasi-in-situ EBSD testing combined with thermal simulation testing machine heating was proposed to observe the grain growth process in the FSW weld. • During post-weld heat treatment, different abnormal grain growth behaviors occur in the stir zone and thermo-mechanically affected zone. • A modified Humphreys’ model was proposed to analyze the abnormal grain growth in the stir zone. • The growth of abnormal grains in the thermo-mechanically affected zone is the process of strain-induced boundary migration. Abnormal grain growth occurs in the friction stir welds of 2219 aluminum alloy during the solution treatment. To further investigate abnormal grain growth, the quasi-in-situ electron backscatter diffraction (EBSD) experiment, including the EBSD testing and heating by thermal simulation testing machine, was proposed to observe the grain growth process in the weld. The results show that the abnormal grain growth behavior in the stir zone and the thermo-mechanically affected zone is different, and different microstructures at different positions in the weld promote the growth of abnormal grains. In the stir zone, the modified Humphreys’ model is used to analyze the abnormal grain growth behavior. The grains with an advantage size and low strain are more likely to grow abnormally. The non-uniform pinning caused by the dissolution of second-phase particles further promotes abnormal grain growth. In the thermo-mechanically affected zone, the abnormal grains are formed by unstrained equiaxed grains near the stir zone or recrystallized sub-grains. The growth of abnormal grains in the thermo-mechanically affected zone is a strain-induced grain boundary migration process. The research is helpful to understand the abnormal grain growth in friction-stir welds during post-weld heat treatment.