Effect of Axial Ultrasonic Vibration on Metal Flow Behavior During Friction Stir Welding

doi:10.11900/0412.1961.2021.00288

Acta Metall Sin

2021, Vol. 57

Issue (12): 1614-1626 DOI: 10.11900/0412.1961.2021.00288

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Effect of Axial Ultrasonic Vibration on Metal Flow Behavior During Friction Stir Welding

HE Changshu¹^,²(

), QIE Mofan¹^,², ZHANG Zhiqiang¹^,², ZHAO Xiang¹^,²

^1.School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China
^2.Key Laboratory for Anisotropy and Texture of Materials, Northeastern University, Shenyang 110819, China

Cite this article:

HE Changshu, QIE Mofan, ZHANG Zhiqiang, ZHAO Xiang. Effect of Axial Ultrasonic Vibration on Metal Flow Behavior During Friction Stir Welding. Acta Metall Sin, 2021, 57(12): 1614-1626.

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Abstract

Metal flow behavior in the stir zone (SZ) is important in friction stir welding (FSW) because it determines the formation of defects, and evolution of microstructure, and affects the mechanical properties of the joint. Applying axial ultrasonic vibration (ultrasonic energy is applied to the stirring tool along the axial direction) during FSW can improve the flowability of SZ metal; however, the reason is unclear. In this study, 6-mm-thick 7N01-T4 alloy plates were welded using FSW and ultrasonic-assisted FSW (UAFSW), using a thin foil of pure aluminum as a marker placed at the butt interface before welding to highlight the actual metal flow during welding. Alongwith the FSW experimental results, the influence of the coupling effect of axial ultrasonic vibration and thread of tool pin on the flow behavior of SZ metal was studied. The results revealed that the macroscopic flow behavior of SZ metal along the welding direction was not affected by axial ultrasonic vibration (e.g., the distance between the arc lines remains unchanged); however, the axial ultrasonic vibration intensified the ring vortex movement of the pin-driven zone (PDZ) metal along the plate-thickness direction. Moreover, the high-frequency forging effect of the shoulder and pin end under the action of ultrasound promoted the flow of metal in the shoulder-driven zone (SDZ) and swirl zone (SWZ). Based on the analysis of the force condition of the plastic metal around the pin, under axial ultrasonic vibration, a microscale sucking-extruding effect model was proposed, and the flowability improvement of SZ metal by axial ultrasonic vibration was explained. The stress superposition and acoustic softening effects induced by ultrasonic vibration are not the only factors affecting the flowability of SZ metal; tool pin geometric features also determine the flow behavior of SZ metal under the action of axial ultrasonic vibration. When a tool with a threaded pin is used for welding, the microscale sucking-extruding effect caused by the coupling of axial ultrasonic vibration and the pin thread improves the SZ metal flowability. When welding using the tool with a smooth pin, axial ultrasonic vibration reduces the shearing effect of the pin on SZ metal, resulting in the weakening of the metal flowability of the SZ, and a high tendency for welding defect formation.

Key words: ultrasonic-assisted friction stir welding marker material tracer technique stir zone metal flow behavior microscale sucking-extruding effect

Received: 12 July 2021

ZTFLH:

TG146.2

Fund: Liaoning Revitalization Talents Program(XLYC1808038)

About author: HE Changshu, associate professor, Tel: (024)83671573, E-mail: changshuhe@mail.neu.edu.cn

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	Changshu HE
	Mofan QIE
	Zhiqiang ZHANG
	Xiang ZHAO

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https://www.ams.org.cn/EN/10.11900/0412.1961.2021.00288 OR https://www.ams.org.cn/EN/Y2021/V57/I12/1614

Fig.1 Experimental setup of ultrasonic-assisted friction stir welding (UAFSW) (a) and geometric dimension of welding tool (d₁—root diameter, 8 mm; d₂—head diameter, 4.8 mm; D—shoulder diameter, 16 mm; H—pin length, 5.8 mm) (b)

Fig.2 Schematics of sampling (a), longitudinal observation section (b), and horizontal observation section (c) (AS—advancing side, RS—retreating side, Z—distance from top surface of joint)

Fig.3 Cross-sectional OM images of the joints welded at rotation rate 1200 r/min and welding rate 160 mm/min (SDZ—shoulder-driven zone, PDZ—pin-driven zone, SWZ—swirl zone, TZ—transition zone)^[22]

Fig.4 OM images of horizontal sections of the stir zone (SZ) at the distance of 0.2 mm from the top surface of the joints welded at rotation rate 1200 r/min and welding rate 160 mm/min

Fig.5 Low (a, b) and locally high (c, d) magnified OM images of horizontal sections of the SZ at the distance of 3.0 mm from the top surface of the joints welded at rotation rate 1200 r/min and welding rate 160 mm/min (WD—welding direction)

Fig.6 Low (a, b) and locally high (c, d) magnified OM images of horizontal sections of the SZ at the distance of 5.2 mm from the top surface of the joints welded at rotation rate 1200 r/min and welding rate 160 mm/min (Arrows in Fig.6d show the intermittent zigzag aluminum foils)

Fig.7 OM images of longitudinal section of the joints welded at rotation rate 1200 r/min and welding rate 160 mm/min

Fig.8 Schematics of force condition of different micro-zones and metal flow in SZ during FSW

Fig.9 Schematics of force condition of different micro-zones and metal flow in SZ during UAFSW

Fig.10 Geometric dimension of smooth pin tool (d₁ = 8 mm, d₂ = 4.8 mm, D = 16 mm, H = 5.8 mm) (a), cross-sectional OM images of FSW (b) and UAFSW (c) joints welded by smooth pin tool under rotation rate 1200 r/min and welding rate 160 mm/min

Fig.11 Distribution characteristics of aluminum foil in the SZ of FSW (a) and UAFSW (b) joints welded by smooth pin tool under rotation rate 1200 r/min and welding rate 160 mm/min

Fig.12 Schematics of microscale sucking-extruding effect produced by different thread features during UAFSW

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