Ultrasonically assisted friction stir welding (UAFSW) was explored. Metallographic structures and material flow prepared by UAFSW were compared with those prepared by conventional FSW. Hardness curves, tensile strength, and elongation of welds fabricated at different ultrasonic powers were characterised. Experimental results showed that hardness curves, tensile strength of welds increased with increased ultrasonic power when it was less than 50%. The elongations decreased with ultrasonic energy output increased. Scanning electron microscopy photographs in different positions of fracture by UAFSW show fracture pattern and origin.
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