Ultrasound-Enhanced Friction Stir Welding of Aluminum Alloy 6082: Advancements in Mechanical Properties and Microstructural Refinement
Marat Rebrin,
Andreas Gester,
Dmitrii Ozherelkov,
Christiane Wächtler,
Toni Sprigode,
Martin Mädlow,
Guntram Wagner
Affiliations
Marat Rebrin
Composites and Material Compounds, Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Straße 73, 09125 Chemnitz, Germany
Andreas Gester
Composites and Material Compounds, Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Straße 73, 09125 Chemnitz, Germany
Dmitrii Ozherelkov
Composites and Material Compounds, Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Straße 73, 09125 Chemnitz, Germany
Christiane Wächtler
Composites and Material Compounds, Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Straße 73, 09125 Chemnitz, Germany
Toni Sprigode
Composites and Material Compounds, Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Straße 73, 09125 Chemnitz, Germany
Martin Mädlow
Process Chain Analysis and Control Department Sensor/Actuator Integration Group, Fraunhofer Institute for Machine Tools and Forming Technology IWU, Nöthnitzer Str. 44, 01187 Dresden, Germany
Guntram Wagner
Composites and Material Compounds, Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Straße 73, 09125 Chemnitz, Germany
This study examines the effects of ultrasound-enhanced friction stir welding (USE-FSW) on the mechanical properties and microstructural characteristics of aluminum alloy AA6082-T6, commonly used in automotive, aerospace, and construction industries. The investigation included tensile and bending tests, as well as detailed microstructural evaluations using scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and energy-dispersive X-ray spectroscopy (EDS). The results indicate that USE-FSW led to an approximately 26% increase in tensile strength compared to similar samples produced by conventional friction stir welding (CFSW). Additionally, the elongation at break improved by around 52%, indicating better ductility. Flexural strength also showed a notable improvement of over 70%. Microstructural analysis revealed a finer grain structure in the stir zone, contributing to these mechanical enhancements. However, the changes in texture and grain orientation were relatively modest, as shown by EBSD and Kernel Average Misorientation (KAM) analyses. Overall, USE-FSW offers incremental improvements in weld quality and mechanical performance, making it a promising technique for producing joints with slightly enhanced strength and ductility.
