Long-term stress relaxation behaviors and mechanisms of 2219 Al–Cu alloy under various temperatures and initial stresses.

• The macroscopic and microscopic features of long-term stress relaxation aging (SRA) under multivariable aging conditions were systematically investigated. • The comprehensive underlying mechanisms of SRA were unraveled considering the interplay between stress relaxation behavior and age-hardening response. • The stress reduction rate rises sharply and the interplaying mechanisms changed greatly when the initial stress or the temperature exceeds a certain threshold. • The strength is enhanced primarily by precipitation strengthening and supplementarily by dislocation strengthening, while SOE degenerates strengthening effect. • There is a strong competition process of enthalpy reduction and entropy increase in the internal energy system composed of the material elastic strain during SRA. Large 2219 Al–Cu alloy aerospace integral components suffer from long-term stress relaxation aging (SRA) due to complex temperature and stress loads during aging treatment/forming and service process, which makes it difficult to ensure their appropriate residual stress and excellent mechanical and service properties. However, the research is limited to a thorough understanding of macroscopic and microscopic features and underlying mechanisms of the long-term SRA under multivariable aging conditions. Therefore, this study investigated macroscopic and microscopic features of long-term SRA under different temperatures (120 °C to 190 °C), initial stress levels (100 MPa to 250 MPa) and durations (0 h to 50 h) through stress relaxation curves, metallographic traits, Vickers hardness, tensile performance, dislocations and phases of precipitation. On the basis of experimental outcomes, the comprehensive mechanisms beneath SRA were unraveled through dislocation theory, multiphase strengthening mechanisms and thermodynamics, where the interplays of stress relaxation behavior with age-hardening response were taken into consideration. The results showed elevations in the rate of stress reduction as the temperature and initial stress rose. At an initial stress greater than the yield stress of alloy, a marked increase in stress relaxation was found, and the mechanisms transform from the intragranular motion of dislocations and diffusion of grain boundaries to the intragranular and intergranular motion of dislocations and migration of grain boundaries. The stress reduction rate rose sharply when the temperature exceeded 175 °C, and the dislocation movement mechanisms transform from gliding to climbing of dislocations. Stress relaxation is in nature progressive transformation of strain from elastic into a permanently inelastic state via the motion of dislocations, leading to the decrease of movable dislocations and the increase of immovable dislocations with more stable configurations. The age hardening is mainly determined by precipitation strengthening, supplementarily by dislocation strengthening, and obvious stress orientation effect (SOE) of G.P. zones and θ" phases degenerates strengthening effect. The interplay between stress relaxation behavior and age-hardening response influences the thermal–mechanical coupling SRA of 2219 Al–Cu alloy, which depends fundamentally on the motion of dislocations and their interplay with precipitated phases. This is a thermal activation process concerning the interplay between internal (age-hardening resistance) stress and external (initial) stress. The initial energy of elastic strain offers Gibbs free energy as the SRA driver, and a steady state of stress relaxation is attained with the lowest energy of elastic strain. These findings provide valuable insights into exploring innovative aging treatment/forming for optimizing residual stress, mechanical performance and service property in a synergistic manner. [Display omitted] [ABSTRACT FROM AUTHOR]