Application for the Way of Ultrasonic Assistance Input and Estimation of its Efficiency for Friction Stir Welding of Aluminum Alloys

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Introduction. Manufacturing capabilities of friction stir welding has some restrictions caused by the formation of welding defects, the alteration in material structure and the appearance of residual stresses that results in worsening of utilization properties of welded joints. A well-known method for improvement of welded joint properties is an input of ultrasonic assistance by different ways during the welding process. However, the application of known ways of the input either requires a complex technique or accompanied by a significant power loss and an attenuation of ultrasonic oscillation. The way for the input of the ultrasonic assistance using a sonotrode fixation on a weld material is seemed to be promising since it has no requirements for a complex technique and provides an effective transmission of the oscillation into the joint formation zone. Goal of this research is the estimation of efficiency of the ultrasonic assistance way, in which the sonotrode fixation is used, by a measuring of the intensity of resulting oscillations and an estimation of its effect on a tensile strength of welded joints obtained by the friction stir welding. Results and discussion. The comparison of two ways of ultrasonic oscillation input is carried out by the means of laser Doppler vibrometry. It’;s shown that the way of input using the sonotrode fixation is more effective that the contact one. The way proposed with much less power input provides 2.5-4.0 times higher intensity of oscillation all over the volume of material not depending of a distance to the point of the oscillation input. Tensile tests of the 2024 alloy samples of joints obtained by friction stir welding demonstrated that the input of ultrasonic oscillation during the welding process results in 10-13% increase of tensile strength. Herewith, the maximum tensile strength achieved 92% of bulk metal. Also it’;s shown that the input of ultrasonic oscillation during the welding process results in strength increasing of material in a stir zone for joints with 2.5 and 5.0 mm thickness and results in reinforcement of a thermomechanically affected zone for joints with 10.0 mm thickness.

About the authors

A. N. Ivanov

Email: ivan@ispms.ru
Institute of Strength Physics and Materials Science of the Siberian Branch of the RAS, 2/4, pr. Akademicheskii, Tomsk, 634055, Russian Federation, ivan@ispms.ru

V. A. Beloborodov

Email: vabel@ispms.ru
Institute of Strength Physics and Materials Science of the Siberian Branch of the RAS, 2/4, pr. Akademicheskii, Tomsk, 634055, Russian Federation, vabel@ispms.ru

V. A. Krasnoveikin

Email: volodia74ms@yandex.ru
Ph.D. (Physics and Mathematics), Institute of Strength Physics and Materials Science of the Siberian Branch of the RAS, 2/4, pr. Akademicheskii, Tomsk, 634055, Russian Federation, volodia74ms@yandex.ru

V. E. Rubtsov

Email: rvy@ispms.ru
Ph.D. (Physics and Mathematics), Institute of Strength Physics and Materials Science of the Siberian Branch of the RAS, 2/4, pr. Akademicheskii, Tomsk, 634055, Russian Federation, rvy@ispms.ru

E. A. Kolubaev

Email: eak@ispms.ru
D.Sc. (Engineering), Institute of Strength Physics and Materials Science of the Siberian Branch of the RAS, 2/4, pr. Akademicheskii, Tomsk, 634055, Russian Federation, eak@ispms.ru

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