Abstract
An elementary analysis is proposed to quantify the effects of ultrasonic vibrations during friction stir welding (FSW) of AA6061-T6 to AZ31B Mg alloy. In the present context, the ultrasonic vibrations are applied in the stirred zone (SZ) via a specially designed welding tool. The influence of ultrasonic vibration has been analyzed for a wide range of welding and rotation speeds. The acoustic addition has proven beneficial to enhance joint strength. Significant diminutions in axial downward force, tool torque, and tool input power equal to ~ 38, 38.7, and 38.75 pct, respectively, have been observed during the ultrasonic addition. Melioration in interfacial bonding, enhanced material mixing, and an improvement in weldment surface quality are observed for ultrasonic joints. For conventional joints, the intermetallic phases βAl3Mg2 and γAl12Mg17 have been found in the SZ and are fragmented under the acoustic influence. The microstructural analysis of the fracture surface shows a ductile fracture mechanism at ultrasonically treated surfaces. A noteworthy grain refinement cum recrystallization is observed in the SZ as well as the immediate deformation zone. The maximum ultrasonic effects are apparent at the weld center and gradually diminish as they move ahead from it.
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