Enhancement of ultrasonic vibration on friction stir welding of high-strength aluminum alloys: Effects on welding loads, microstructures, and mechanical properties of joints

Enhancement of ultrasonic vibration on friction stir welding of high-strength aluminum alloys: Effects on welding loads, microstructures, and mechanical properties of joints

In this study, a coaxial ultrasonic-assisted friction stir welding (UFSW) system with an automatic frequency tracking function was developed to enhance the effectiveness of ultrasonic vibration and to increase the integration and accessibility of the UFSW system. 2219-T6 aluminum alloy was welded us...

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Bibliographic Details
Main Authors: Zhongxue Jia, Yunqiang Zhao, Guoqing Duan, Korzhyk Volodymyr, Haokun Yang, Zhe Liu, Zhicheng Lin, Yevhenii Illiashenko, Igor Krivtsun
Format: Article
Language:English
Published: Elsevier 2025-05-01
Series:Journal of Materials Research and Technology
Subjects:
Friction stir welding
Ultrasonic
Welding tool
Microstructure
Mechanical property
Online Access:http://www.sciencedirect.com/science/article/pii/S2238785425013274
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Summary:In this study, a coaxial ultrasonic-assisted friction stir welding (UFSW) system with an automatic frequency tracking function was developed to enhance the effectiveness of ultrasonic vibration and to increase the integration and accessibility of the UFSW system. 2219-T6 aluminum alloy was welded using this UFSW system. The findings demonstrated that the FSW parameter window was broadened and the welding pressure, torque, and temperature were also significantly reduced as a result of the successful introduction of ultrasonic vibration. Furthermore, the enhanced ultrasonic effects of this novel UFSW system not only promoted recrystallization of grains in the stir zone (SZ) and weakened texture intensity but also facilitated the subsequent grain growth process. Within the same welding parameter range, compared to the conventional friction stir welding (FSW), the tensile strengths and elongations of UFSW joints increased by 1.1 %–8.7 %, and 19.6 %–111 %, respectively. At the optimal welding parameters (800 rpm, 500 mm/min, 0.2 mm penetration depth), the UFSW joint achieved a tensile strength of 361 MPa and an elongation of 6.1 %. The reduction in welding temperature inhibits the dissolution of the θ′ phase within the SZ of the UFSW joints, which is the primary mechanism for joint strengthening.
ISSN:2238-7854

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