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<p>This study investigates the effect of various parameters on the joint strength of 6061-T6 aluminum alloy during Refill Friction Stir Spot Welding assisted by ultrasonic waves. Using a test rig designed for both horizontal and vertical ultrasonic applications, three key parameters were analyzed: tool rotation speed, tool penetration depth, and ultrasonic power, each with three levels. A total of 20 experimental runs were conducted, and joint strength was measured using a universal testing machine. Statistical analysis, including Analysis of Variance (ANOVA) and regression analysis, was employed to evaluate significant effects and optimize parameters. The results indicate an optimal tool speed of around 1700&#xa0;rpm for vertical welding, enhancing joint strength until excessive heat generation negatively impacts it. While penetration depth has a minor influence, increased ultrasonic power significantly improves strength in vertical welding due to enhanced material flow. Conversely, horizontal ultrasonic welding exhibited minimal strength improvements with higher power due to a lack of effective compression at the joint surfaces. Microstructural analysis revealed finer grains in areas subjected to higher ultrasonic power, attributed to recovery and dynamic recrystallization processes. The findings underscore the complex interplay between process parameters and material properties, highlighting the potential for optimizing ultrasonic welding conditions to achieve superior joint strength.</p>

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Optimizing joint strength in refill friction stir spot welding of 6061-T6 aluminum alloy assisted ultrasonic waves: an experimental study on process parameters

  • 期刊论文

  • 发表日期：

    2025年6月5日

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  • Esmaeel Poor Esmaeel,
  • Masoud Mahmoodi,
  • Seyed Mohammad Jafari

摘要

This study investigates the effect of various parameters on the joint strength of 6061-T6 aluminum alloy during Refill Friction Stir Spot Welding assisted by ultrasonic waves. Using a test rig designed for both horizontal and vertical ultrasonic applications, three key parameters were analyzed: tool rotation speed, tool penetration depth, and ultrasonic power, each with three levels. A total of 20 experimental runs were conducted, and joint strength was measured using a universal testing machine. Statistical analysis, including Analysis of Variance (ANOVA) and regression analysis, was employed to evaluate significant effects and optimize parameters. The results indicate an optimal tool speed of around 1700 rpm for vertical welding, enhancing joint strength until excessive heat generation negatively impacts it. While penetration depth has a minor influence, increased ultrasonic power significantly improves strength in vertical welding due to enhanced material flow. Conversely, horizontal ultrasonic welding exhibited minimal strength improvements with higher power due to a lack of effective compression at the joint surfaces. Microstructural analysis revealed finer grains in areas subjected to higher ultrasonic power, attributed to recovery and dynamic recrystallization processes. The findings underscore the complex interplay between process parameters and material properties, highlighting the potential for optimizing ultrasonic welding conditions to achieve superior joint strength.