Ultrasonic vibration-assisted welding process was developed to improve the microstructures and mechanical properties of AZ80 Mg alloy joints. Results show that the ultrasonic vibration-assisted welding process has a significant effect on the morphology and size of both β-Mg17Al12 precipitated phases and α-Mg grains. With ultrasonic vibration treatment, the primary α-Mg grains are transformed from coarse dendrites to nearly fine equiaxed grains, and the β-Mg17Al12 phases at α-Mg boundaries are refined and become discontinuous, owing to the cavitation effects and acoustic streaming effects induced by ultrasonic vibration. The mechanical properties of AZ80 Mg alloy joints under the ultrasonic vibration-assisted process are obviously improved. And the influence mechanisms of the ultrasonic vibration-assisted welding process on joints are discussed in detail.
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