Abstract
In ultrasonic assisted friction stir welding (UaFSW) system, the ultrasonic vibration is exerted onto the tool radially, and can achieve synchronously thermo-mechanical action with the tool. A mathematical model is established to investigate the coupled “acoustic action-heat generation-plastic deformation” behaviors in UaFSW. The ultrasonic stress work is considered to revise both the constitutive equation and the slip rate. In UaFSW the ultrasound vibrates along the welding direction and the peak acoustic pressures at both leading and trailing sides enhance the material plastic flow there. It is found that the ultrasound increase the percentage of viscous dissipation heat in the total heat generation. It is the acoustic softening effect, not the supplemented ultrasonic energy, which plays a dominate role in UaFSW. The numerical results are compared and experimentally verified with the thermal cycle at typical positions and the cross section of weld zone respectively.
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