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<p>In recent years, ultrasonic surface rolling processing (USRP) technology for aluminum alloys has garnered significant attention, with most studies focusing on the 7xxx series aluminum alloys, while research on 6061 aluminum alloy remains relatively limited. This study systematically and thoroughly investigates the surface performance of 6061 aluminum alloy, combining simulation experiments to explore USRP strengthening. Through finite element simulation analysis and USRP experiments, the effects of different USRP processing parameters on the gradient residual compressive stress, microstructure, hardness, surface roughness, surface morphology, and corrosion resistance of 6061 aluminum alloy were examined. The research found that USRP can significantly refine the grains of 6061 aluminum alloy, influence the composition of AlFeSi phases, form a gradient deformation layer, and enhance surface hardness and corrosion resistance. By optimizing USRP process parameters, the best surface roughness and significantly improved fatigue resistance can be achieved. When the static load is 500 N, the amplitude is 5&#xa0;μm, and the step distance is 0.1&#xa0;mm, the surface roughness is minimized, and the corrosion resistance is optimal. Additionally, when the amplitude is 7&#xa0;μm, the surface hardness reaches its maximum, increasing by approximately 30%. These research findings provide theoretical and practical guidance for improving the fatigue life of high-end components made from 6061 aluminum alloy.</p>

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Behavior Analysis and Performance Optimization of 6061 Aluminum Alloy by Using Ultrasonic Surface Rolling Process

  • 期刊论文

  • 发表日期：

    2025年6月18日

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  • Ying Zhao,
  • Shubo Xu,
  • Xue Yang,
  • Xiaodong Yu,
  • Xiquan Ma,
  • Renhui Liu,
  • Kangwei Sun,
  • Xiaoyu Ju,
  • Chen Xu,
  • Wei Zheng

摘要

In recent years, ultrasonic surface rolling processing (USRP) technology for aluminum alloys has garnered significant attention, with most studies focusing on the 7xxx series aluminum alloys, while research on 6061 aluminum alloy remains relatively limited. This study systematically and thoroughly investigates the surface performance of 6061 aluminum alloy, combining simulation experiments to explore USRP strengthening. Through finite element simulation analysis and USRP experiments, the effects of different USRP processing parameters on the gradient residual compressive stress, microstructure, hardness, surface roughness, surface morphology, and corrosion resistance of 6061 aluminum alloy were examined. The research found that USRP can significantly refine the grains of 6061 aluminum alloy, influence the composition of AlFeSi phases, form a gradient deformation layer, and enhance surface hardness and corrosion resistance. By optimizing USRP process parameters, the best surface roughness and significantly improved fatigue resistance can be achieved. When the static load is 500 N, the amplitude is 5 μm, and the step distance is 0.1 mm, the surface roughness is minimized, and the corrosion resistance is optimal. Additionally, when the amplitude is 7 μm, the surface hardness reaches its maximum, increasing by approximately 30%. These research findings provide theoretical and practical guidance for improving the fatigue life of high-end components made from 6061 aluminum alloy.