Abstract
In recent years, ultrasonic vibration has been integrated with various types of manufacturing processes, and researchers reported enhancement of the process efficiency while applying this method. In the present study, a vertical high-frequency vibration is applied on friction stir tool to determine its effects on tensile strength and formability (as characteristics of mechanical properties) as well as surface quality and sliding wear rate (as characteristics of tribological properties) of the welded AA6061. L9 Taguchi design was used to conduct the experiments and analyze effect of factors on mentioned quality characteristics. The four major parameters are ultrasonic power, tool rotary speed, traverse speed, and axial force. Also, the optimal welding conditions to maximize the tensile strength and formability and minimize the surface roughness and sliding wear rate were identified using grey relational analysis and reported here. Results indicated that the vibration power is a most significant factor having positive influence on both mechanical and tribological properties of welded samples.
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