Improved weld macrosection,microstructure and mechanical properties of 2024Al-T4 butt joints in ultrasonic vibration enhanced friction stir welding

Ultrasonic vibration enhanced friction stir welding (UVeFSW) is a new variant of friction stir welding (FSW) in which a sonotrode transmits ultrasonic energy directly into the localised area of the workpiece near and ahead of the rotating tool. This study investigated the influence of ultrasonic vibration on the formation, microstructure and mechanical properties of butt welded 2024Al-T4 joints, and attempted to unveil the underlying mechanism of UVeFSW by experimental methods. Morphology inspection, X-ray detection and metallographic inspection of the welds revealed that ultrasonic vibration can improve the weld formation at higher welding speeds. The stir zone in the UVeFSW broadened, while the grains in the heat affected zone had no obvious growth contrary to that in the base metal. Results of the mechanical tests indicated that the tensile strength and elongation of joints, and the microhardness value in the stir zone increased at the same welding parameters.