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<p>The experiments were performed on AA6082-AA7075-T6 sheets using the UAFSW (Ultrasonic-Assisted Friction Stir Welding) configuration. The experimental variables encompassed in the study comprised tilt angle, rotational speed, traversal speed, amplitude, and forms of vibration. The experimental results demonstrate that the residual stress in the welded zone varies between − 54.66 and − 11&#xa0;MPa, while the residual stress in the base metal is − 176&#xa0;MPa. A negative sign signifies that the residual stresses have a compressive nature. The research findings have determined that a contribution of 39.23 percent is the most optimal degree for reaching the highest rotational speed. The vibration type is influenced by different characteristics as follows: 12.24 percent by contribution, 17.64 percent by tilt angle, 5.6 percent by travel speed, and 16.19 percent by amplitude type. The tribological test results demonstrated a notable decrease in the coefficient of friction (COF) by 72.88% and a major reduction in wear by 71%. The aforementioned results were obtained by conducting tests under controlled conditions, which involved a sliding velocity of 1&#xa0;m/s, a temperature of 350&#xa0;°C, and a weight of 150N, using the Ultrasonic-Assisted Friction Stir Welding (UAFSW). The correlation between the coefficient of friction (COF) and sliding distance indicates that the base metal displays the highest COF values, but the use of vibration in friction stir welding (FSW) leads to a reduction in COF. The coefficient of friction (COF) reaches its minimum value when an UAFSW is exposed to intermittent vibrations. The wear suffered during sliding is most significant in the base metal, but it decreases when vibration is applied in the context of friction stir welding (FSW). When intermittent vibrations are applied, UAFSW demonstrates the lowest coefficient of friction (COF).</p>

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Optimization and Evaluation of Residual Stress in Dissimilar AA6082–AA7075 Alloys Welded by Ultrasonic FSW under Temperature-Dependent Conditions

  • 期刊论文

  • 发表日期：

    2026年2月17日

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  • Shanti Lal Meena,
  • Ankit Tyagi,
  • Amit Kumar

摘要

The experiments were performed on AA6082-AA7075-T6 sheets using the UAFSW (Ultrasonic-Assisted Friction Stir Welding) configuration. The experimental variables encompassed in the study comprised tilt angle, rotational speed, traversal speed, amplitude, and forms of vibration. The experimental results demonstrate that the residual stress in the welded zone varies between − 54.66 and − 11 MPa, while the residual stress in the base metal is − 176 MPa. A negative sign signifies that the residual stresses have a compressive nature. The research findings have determined that a contribution of 39.23 percent is the most optimal degree for reaching the highest rotational speed. The vibration type is influenced by different characteristics as follows: 12.24 percent by contribution, 17.64 percent by tilt angle, 5.6 percent by travel speed, and 16.19 percent by amplitude type. The tribological test results demonstrated a notable decrease in the coefficient of friction (COF) by 72.88% and a major reduction in wear by 71%. The aforementioned results were obtained by conducting tests under controlled conditions, which involved a sliding velocity of 1 m/s, a temperature of 350 °C, and a weight of 150N, using the Ultrasonic-Assisted Friction Stir Welding (UAFSW). The correlation between the coefficient of friction (COF) and sliding distance indicates that the base metal displays the highest COF values, but the use of vibration in friction stir welding (FSW) leads to a reduction in COF. The coefficient of friction (COF) reaches its minimum value when an UAFSW is exposed to intermittent vibrations. The wear suffered during sliding is most significant in the base metal, but it decreases when vibration is applied in the context of friction stir welding (FSW). When intermittent vibrations are applied, UAFSW demonstrates the lowest coefficient of friction (COF).