Recent Progress in Process and Mechanical Properties of Ultrasonic-Assisted Friction Stir Welding of Aluminum Alloys: A Review

Xuliang Kong; Ying Meng; Lei Wang

doi:10.54097/309c2891

Authors

Xuliang Kong Hebei Mechanical and Electrical Polytechnic, Xingtai 054000, China
Ying Meng Hebei Mechanical and Electrical Polytechnic, Xingtai 054000, China
Lei Wang Hebei Mechanical and Electrical Polytechnic, Xingtai 054000, China

DOI:

https://doi.org/10.54097/309c2891

Keywords:

Ultrasonic-assisted friction stir welding; Aluminum alloys; Microstructure; Mechanical properties.

Abstract

Aluminum alloys, as pivotal structural materials for lightweight manufacturing, have been extensively applied in cutting-edge industries such as aerospace, rail transit, and automotive engineering. However, the conventional solid-state joining technology, friction stir welding (FSW), often faces critical bottlenecks when processing ultra-high-strength aluminum alloys or dissimilar materials, including non-uniform heat input, excessive tool wear induced by high axial forces, restricted grain refinement, and a high susceptibility to welding defects like tunneling and kissing bonds. As an advanced solid-state hybrid joining technology that deeply integrates a high-frequency acoustic field with a thermal-mechanical coupled field, ultrasonic-assisted friction stir welding (UAFSW) introduces high-frequency ultrasonic vibrations during the welding process. This hybrid process significantly improves the rheological characteristics of plasticized metals, reduces mechanical loads, and refines the joint microstructure. This paper systematically reviews recent research progress in UAFSW for both similar and dissimilar aluminum alloys. Special emphasis is placed on elucidating the underlying mechanisms of microstructural reconstruction and mechanical performance enhancement driven by the acoustic volume and acoustic surface effects. Furthermore, representative process parameters and experimental data are comprehensively deconstructed, followed by an outline of key future research trends in this field.

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