Joining Two Dissimilar Metals of Aluminum 5052 to Austenitic Stainless Steel 304 using Ultrasonic Friction Stir Welding

In this research, the joining of aluminum alloy 5052 to austenitic stainless steel 304 was investigated. For this purpose, friction stir welding process was used in two modes with and without ultrasonic vibrations. In order to achieve the best welding quality in terms of mechanical and metallurgical properties, welding parameters such as rotational speed, linear speed and frequency were investigated. The aim of this research is to obtain a sample with the best mechanical and metallurgical properties and the lowest residual stress. As a research innovation and the aim of measuring the values of residual stress created in the samples after the welding operation, the new method of drilling and Digital Image Correlation was used. Finally, by examining the results, it has been determined that ultrasonic vibrations have improved the mechanical and metallurgical properties about 15% to a large extent. In order to evaluate the accuracy of the results related to the residual stress, all the samples were subjected to the central drilling test by installing a strain gauge, and it was found that the error is less than 10% and obtained results were accurate and appropriate.