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<p>This study explored the use of composite fillers and ultrasonic vibration treatment (UVT) to enhance the strength and ductility of Al 2024 weldments. A combination of Al 4043 (filler matrix) and ZrB<sub>2</sub> (reinforcement material) was used to synthesize microcomposite (MC) and nanocomposite (NC) fillers via in-situ salt melt and ultrasonic melt treatment processes, respectively. XRD confirmed ZrB<sub>2</sub> in synthesized NC fillers, validated by TEM showing 38 ± 12&#xa0;nm nanoparticles. Optical microscopy revealed SDAS reduction from 15 ± 4.2 to 6 ± 2.2&#xa0;µm, enhancing grain refinement. NC fillers exhibited high microhardness (89 ± 2 HV<sub>0.2</sub>). TIG welding with NC fillers and UVT produced weldments exhibiting superior tensile strength (245.43&#xa0;MPa) and elongation (13%), demonstrating enhanced mechanical properties and ductility compared to welding without UVT. Mechanical properties of welds were compared to as-cast Al 2024 (YS: 94&#xa0;MPa, UTS: ~ 222&#xa0;MPa, elongation: 17%) due to microstructural similarities. The NC filler with UVT achieved weld strengths matching or exceeding the base alloy, demonstrating effectiveness within the metallurgical limits of fusion welding. Weibull analysis confirmed improved strength reliability and reduced variability. This study underscores ultrasonically treated NC fillers and UVT as a promising method to enhance weld quality and performance for engineering applications.</p>

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Enhancing Strength and Reliability of Ultrasonic Assisted TIG Welded Al 2024 Joints Using Al 4043/ZrB2 Nanocomposite Fillers

  • 期刊论文

  • 发表日期：

    2025年11月6日

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  • R. Gokul Raju,
  • Jayakrishnan Nampoothiri,
  • A. Dhilip

摘要

This study explored the use of composite fillers and ultrasonic vibration treatment (UVT) to enhance the strength and ductility of Al 2024 weldments. A combination of Al 4043 (filler matrix) and ZrB2 (reinforcement material) was used to synthesize microcomposite (MC) and nanocomposite (NC) fillers via in-situ salt melt and ultrasonic melt treatment processes, respectively. XRD confirmed ZrB2 in synthesized NC fillers, validated by TEM showing 38 ± 12 nm nanoparticles. Optical microscopy revealed SDAS reduction from 15 ± 4.2 to 6 ± 2.2 µm, enhancing grain refinement. NC fillers exhibited high microhardness (89 ± 2 HV0.2). TIG welding with NC fillers and UVT produced weldments exhibiting superior tensile strength (245.43 MPa) and elongation (13%), demonstrating enhanced mechanical properties and ductility compared to welding without UVT. Mechanical properties of welds were compared to as-cast Al 2024 (YS: 94 MPa, UTS: ~ 222 MPa, elongation: 17%) due to microstructural similarities. The NC filler with UVT achieved weld strengths matching or exceeding the base alloy, demonstrating effectiveness within the metallurgical limits of fusion welding. Weibull analysis confirmed improved strength reliability and reduced variability. This study underscores ultrasonically treated NC fillers and UVT as a promising method to enhance weld quality and performance for engineering applications.