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Hybrid Friction Stir Welding: The Role of Ultrasonic Vibration and Tool Rotation in Enhancing the Joint Properties
Mechanical and Construction Engineering Department, Northumbria University, Newcastle (GBR); Mechanical Engineering Department, Faculty of Engineering, Benha University, Benha (EGY).
Mechanical and Construction Engineering Department, Northumbria University, Newcastle (GBR).
Mechanical and Construction Engineering Department, Northumbria University, Newcastle (GBR).
Computer and Information Sciences Department, Northumbria University, Newcastle (GBR).
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2025 (English)In: Journal of Physics, Conference Series, ISSN 1742-6588, E-ISSN 1742-6596, Vol. 3058, no 1, article id 012012Article in journal (Refereed) Published
Abstract [en]

Aluminum-lithium (Al-Li) alloys have gained considerable attention in the aerospace sector due to their superior mechanical properties and strength-To-weight ratio. However, joining these alloys through fusion welding presents challenges including solidification cracking. Friction Stir Welding (FSW) has emerged as a viable solution, offering improved mechanical performance and minimized defects. Recently, ultrasonic vibration-Assisted FSW (UVaFSW) has been introduced to further enhance weld quality by refining grain structure and improving plastic flow. This study investigates the impact of UVaFSW parameters, specifically tool rotational speed (TRS) and vibration amplitude (Amp), on the microstructural and mechanical properties of AA2060-T8E30 Al-Li alloy widely utilized in the aviation sector. The experimental analysis reveals that TRS of 800 rpm results in enhanced tensile strength, while higher TRS (1600 rpm) induces excessive heat, leading to grain coarsening and reduced mechanical performance. Additionally, increasing vibration amplitude from 7.5 ÎŒm to 22.5 ÎŒm significantly improves the welded joints quality. The findings emphasize the potential of UVaFSW in enhancing welding of Al-Li alloy, offering a suitable approach for high-performance aerospace applications.  

Place, publisher, year, edition, pages
Institute of Physics , 2025. Vol. 3058, no 1, article id 012012
Keywords [en]
Aerospace applications; Aerospace industry; Aluminum alloys; Aviation; Binary alloys; Coarsening; Friction; Friction stir welding; Lithium alloys; Research laboratories; Solidification; Ultrasonic effects; Ultrasonic waves; Vibrations (mechanical); Welds; Aluminium-lithium alloys; Aluminum lithium alloy; Friction-stir-welding; Mechanical; Mechanical performance; Property; Rotational speed; Ultrasonic-vibration; Vibration amplitude; Vibration assisted; Tensile strength
National Category
Manufacturing, Surface and Joining Technology Metallurgy and Metallic Materials Applied Mechanics
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-23939DOI: 10.1088/1742-6596/3058/1/012012Scopus ID: 2-s2.0-105012205618OAI: oai:DiVA.org:hv-23939DiVA, id: diva2:2025884
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Available from: 2026-01-08 Created: 2026-01-08 Last updated: 2026-01-08

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Patel, Vivek

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