In the study

friction pull plug welding (FPPW) process of 6–8mm thick 2219–T87 aluminum alloy was discussed. The results show that the structure of the plug and hole

the forming hole and the main welding parameters (axial load

welding speed and feed speed) have important influence on the weld formation. The use of circular arc-shaped plug rod

cylindrical plug hole and stepped tapered bottom hole can improve the flow direction and stress conditions of the base material and eliminate the unwelded defects. The welding speed is 7000r/min

the welding pressure is 20kN

the axial forging force is 20–30kN

and the feeding speed is 1.5mm/s. In the welded joint

the softening in the thermal mechanically affect zone on the base material side is the most obvious

and the hardness value is 79.9HV. Under the optimized parameters

the tensile strength of the welded joint can reach 365MPa

and the elongation is 6%

which is equivalent to 80% of the base metal.