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Titanium as a high-performance material offers great potential for a wide range of applications with different aspects like lightweight-constructions, biocompatibility as well as design and is used in various industrial areas like the transportation sector or in medical and sports engineering. To exploit the full potential of titanium, there is still a need for innovative and efficient joining techniques compared to conventional methods. The process of friction stir welding as a solid-state joining method is able to produce high-quality similar joints of titanium. Nevertheless, there are still some challenging aspects when friction stir welding titanium like the formation of oxide layers that affect the mechanical properties especially in the field of fatigue negatively. The superposition of power ultrasound on the friction stir welding process can address this issue. Therefore, the hybrid process of ultrasound enhanced friction stir welding was applied on similar Ti6Al4V/Ti6Al4V joints in a butt joint configuration to reduce the amount of oxide layers and improve the fatigue lifetime of the joints. For the joint configuration, a positive impact of the power ultrasound could be identified by the breakup of oxide layers and an increase in the tensile strength of 16%. Also stepwise load increase tests revealed a higher estimated fatigue strength for ultrasound enhanced friction stir welded specimen in this butt joint configuration.

Comparison of process behavior, microstructure and mechanical properties of ultrasound enhanced friction stir welded titanium/titanium joints