Abstract

The optimization mechanism of ultrasonic power on the performance of aluminum/steel dissimilar metal ultrasonic vibration enhanced friction stir welding (UVeFSW) joints was studied. The results indicated that ultrasonic vibration can significantly improve the surface forming quality of the weld seam, increase the width of the joint interface zone, adjust the height of the hook structure, suppress the generation of intermetallic compounds, and enhance the failure load of the joints. When the ultrasonic power was 500 W, the lap joints with the best mechanical properties were obtained, and its failure load was 5.14 kN, which was 51.2% higher than that of conventional FSW (0 W).

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