scholarly journals Conversion of a Conventional Lathe Machine into a Friction Welding Machine and Performing Some Experimental Tests for its Operational Feasibility

2021 ◽  
Vol 40 (3) ◽  
pp. 545-555
Author(s):  
Kamran Shah ◽  
Hassan Khurshid ◽  
Izhar Ul Haq ◽  
Nauman Khurram ◽  
Zeeshan Ali
Keyword(s):  
Friction Welding ◽  
Applied Pressure ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Experimental Tests ◽  
Cost Effective ◽  
High Productivity ◽  
Welding Machine ◽  
Lathe Machine ◽  
Welding Processes

In today’s manufacturing environment, there is always a need to use cost effective methods and materials for production purposes. Friction welding is one of such method that offers cost effectiveness and high productivity rate as compared to other similar welding processes. Friction welding process has been used widely in the manufacturing world. It is an adjustable and tolerant process that can join most engineering materials. It is a well-established welding process that can produce good quality weldment between similar and dissimilar materials. Due to this flexibility of use of different materials, it has been used in many applications such as aerospace, automotive and other related manufacturing industries etc. The main objective of this research is to study possibility of doing friction-welding on a typical lathe machine instead of doing it on a friction welding machine and also to check the reliability of the welded joint. Conventional Lathe machine was converted into a friction-welding machine by adopting a systematic procedure. The fixture of the attachment was designed, manufactured and installed and different parameters such as applied pressure and spindle rpm were tested in order to achieve the welding joint by friction. The materials used for welding were Stainless Steel 070M20 and Aluminum 2011-T3.

scholarly journals FEM Simulation and Experimental Tests on the SMAW Welding of a Dissimilar T-Joint

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1016
Author(s):  
Raffaele Sepe ◽  
Venanzio Giannella ◽  
Alessandro Greco ◽  
Alessandro De Luca
Keyword(s):  
Fem Simulation ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Experimental Tests ◽  
Fe Model ◽  
Shielded Metal Arc Welding ◽  
Fe Modelling ◽  
Metal Arc Welding ◽  
High Level ◽  
Welding Processes

Residual stresses induced by the welding processes may, in some cases, result in significant warping and distortions that can endanger the integrity of the welded structures. This document reports an investigation of the welding process to make a dissimilar T-joint through an advanced Finite Element (FE) modelling and a dedicated laboratory test. The T-joint consisted of two plates of dissimilar materials, AISI304 and S275JR steels, both having a thickness of 5 mm, welded through a Shielded Metal Arc Welding (SMAW). Thermocouples were used to acquire the temperature variations during welding. In parallel, an FE model was built and the welding process was simulated through the “element birth and death” technique. Numerical and experimental outcomes were compared in terms of temperature distributions during welding and in terms of distortion at the end of the final cooling, showing that the FE model was able to provide a high level of accuracy.

scholarly journals Review of Experimental Investigations in Friction Welding Technique

2017 ◽  
Vol 7 (2 (S)) ◽  
pp. 373
Author(s):  
Gurunath Shinde ◽  
Prakash Dabeer
Keyword(s):  
Friction Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
The Other ◽  
Experimental Investigations ◽  
Rotating Speed ◽  
Friction Pressure ◽  
Paper Review ◽  
Welding Processes ◽  
Welding Technique

<p>Friction welding is a solid state welding processes in which the weld is obtained by the heat generated due to forging and friction. Now a day’s eco-friendly joining of dissimilar materials is the need of the industries. The advantages of friction welding process are reduction in production time and cost saving. Friction welding is classified into two types. One type is Inertia drive friction welding and the other is Continuous drive friction welding. In continuous drive friction welding one of the work pieces is held stationary while the other is held for a certain rotating speed. The two work pieces are brought together under certain friction pressure for a<br />certain period of time known as friction time. Then, the rotation is stopped and upset pressure is applied for a certain upset time. Then, the spindle is disengaged and the component is unloaded. In Inertia drive friction welding one part is held stationary while the other is clamped in the chuck which is attached to the flywheel. The flywheel and chuck is rotated for a certain seed to store a predetermined energy. In this paper, review of friction welding on different materials and their weld ability has been discussed in brief.</p>

Interfacial Microstructure and Strength of Friction Welding of Steel Tube to Aluminium Tube Plate Using an External Tool

2011 ◽  
Vol 383-390 ◽  
pp. 877-881 ◽  
Author(s):  
S. Muthukumaran ◽  
C. Vijaya Kumar ◽  
S. Senthil Kumaran ◽  
A. Pradeep
Keyword(s):  
Friction Welding ◽  
Thermal Power ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Industrial Applications ◽  
Interfacial Microstructure ◽  
Steel Tube ◽  
Tube Plate ◽  
Wide Range ◽  
Interface Hardness

Joining of dissimilar materials is of increasing interest for a wide range of industrial applications like nuclear, thermal power. The automotive industry, in particular, views dissimilar materials joining as a gateway for the implementation of lightweight materials. Friction welding of tube to tube plate using an external tool is an innovative friction welding process and is capable of producing high quality leak proof weld joints. In the present study, friction welding of steel tube to commercial aluminum tube plate using an external tool with and without tube projection have been performed. The joints were evaluated by mechanical testing and metallurgical analysis. The results of bonding interface hardness and joint strength reveal that steel tube with projection are better than the steel tube without projection.

Sequential Transient Numerical Simulation of Inertia Friction Welding Process

2008 ◽  
Author(s):  
Medhat Awad El-Hadek ◽  
Mohammad S. Davoud
Keyword(s):  
Temperature Distribution ◽  
Residual Stresses ◽  
Friction Welding ◽  
Welding Process ◽  
Transient Temperature ◽  
Inertia Friction Welding ◽  
Residual Stress Field ◽  
Element Analysis ◽  
Full Field ◽  
Welding Processes

Inertia friction welding processes often generate substantial residual stresses due to the heterogeneous temperature distribution during the welding process. The residual stresses which are the results of incompatible elastic and plastic deformations in weldment will alter the performance of welded structures. In this study, three-dimensional (3D) finite element analysis has been performed to analyze the coupled thermo-mechanical problem of inertia friction welding of a hollow cylinder. The analyses include the effect of conduction and convection heat transfer in conjunction with the angular velocity and the thrust pressure. The results include joint deformation and a full-field view of the residual stress field and the transient temperature distribution field in the weldment. The shape of deformation matches the experimental results reported in the literature. The residual stresses in the heat-affected zone have a high magnitude but comparatively are smaller than the yield strength of the material.

scholarly journals Friction Welding of Aluminium and Aluminium Alloys with Steel

2014 ◽  
Vol 2014 ◽  
pp. 1-15 ◽  
Author(s):  
Andrzej Ambroziak ◽  
Marcin Korzeniowski ◽  
Paweł Kustroń ◽  
Marcin Winnicki ◽  
Paweł Sokołowski ◽  
...  
Keyword(s):  
Friction Welding ◽  
Aluminium Alloys ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Tensile Tests ◽  
Optimal Parameters ◽  
Bending Tests ◽  
Actual Knowledge ◽  
Different Types ◽  
Selection Of

The paper presents our actual knowledge and experience in joining dissimilar materials with the use of friction welding method. The joints of aluminium and aluminium alloys with the different types of steel were studied. The structural effects occurring during the welding process were described. The mechanical properties using, for example, (i) microhardness measurements, (ii) tensile tests, (iii) bending tests, and (iv) shearing tests were determined. In order to obtain high-quality joints the influence of different configurations of the process such as (i) changing the geometry of bonding surface, (ii) using the interlayer, or (iii) heat treatment was analyzed. Finally, the issues related to the selection of optimal parameters of friction welding process were also investigated.

scholarly journals FINITE ELEMENT BASED THERMAL MODELING OF FRICTION WELDING OF DISSIMILAR MATERIALS

2013 ◽  
Vol 22 ◽  
pp. 196-202 ◽  
Author(s):  
N. RAJESH JESUDOSS HYNES ◽  
P. NAGARAJ ◽  
R. MEBY SELVARAJ
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Friction Welding ◽  
Thermal Modeling ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Element Approach ◽  
Stress Formation ◽  
Role Based ◽  
Solid State Joining

Friction welding is a solid state joining process of joining either similar or dissimilar materials. Joining of ceramic/metal joints by friction welding has opened up new possibilities in many engineering applications. In the present work, thermal modeling of friction welding process has been carried out. Using Finite Element Approach (FEA), analytical solutions were arrived for different ceramic/metal combinations. The temperature distributions of cylindrical surfaces of the alumina and the metals are found by means of 1D heat transfer assumption considering the effect of convection. In the thermal analysis, interfacial temperature and thermal conductivity of the material play a significant role. Based on the obtained temperature distribution the graphs are plotted between the length of the joint and the temperatures. Thus the knowledge of the temperature joint distribution could be helpful in predicting the thermal cycle of the process, microstructure evolution and residual stress formation. Thus the obtained graph helps to study and predict the temperature distribution of both the materials.

Residual Stresses Evaluation on Radial Friction Welded Joints

2005 ◽  
Author(s):  
Rosa Irene Terra Pinto ◽  
Telmo Roberto Strohaecker
Keyword(s):  
Residual Stresses ◽  
Friction Welding ◽  
Deformation Gradient ◽  
Welding Process ◽  
Hole Drilling ◽  
Welding Parameters ◽  
Hole Drilling Method ◽  
Joint Quality ◽  
Welding Processes

The Radial Friction Welding (RFW) is a solid-state welding process in which two long elements of several metallic alloys can be joined, without the occurrence of common problems to the conventional welding processes that include fusion. During friction welding the temperature evolution is directly related with the deformation gradient, and these fields govern the joint properties. In this work, the finite element method was used to solve the full coupled termomechanical problem in order to determine the deformation and the stress fields and the variation of the temperature during RFW process. The simulation of the RFW process permitted to establish the influence of the welding parameters, like rotation and approximation speed, on the joint quality. Furthermore, the knowledge of the temperature gradient and cooling rates allowed the prediction of the resulting microestruture and determination of the level of residual stresses of the joint. To verify the analytical results the determination of the residual stresses was accomplished by the hole drilling method in several points along the perimeter of two welded workpieces.

Characterization of Friction Welding for IN713LC and AISI 4140 Steel

2004 ◽  
Vol 449-452 ◽  
pp. 53-56 ◽  
Author(s):  
Jong Taek Yeom ◽  
J.H. Park ◽  
J.W. Lee ◽  
Nho Kwang Park
Keyword(s):  
Heat Affected Zone ◽  
Friction Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
State Variables ◽  
Aisi 4140 Steel ◽  
Aisi 4140 ◽  
Bending Stresses ◽  
Deform 2D ◽  
Friction Weld

Friction welding of dissimilar materials, Ni-base superalloy IN713LC and oil-quench plus tempered AISI 4140 steel, was investigated. Friction welding was carried out with various process variables such as friction pressure and time. The quality of welded joints was tested by applying bending stresses in an appropriate jig. Microstructures of the heat-affected zone (HAZ) were investigated along with micro-hardness tests over the friction weld joints. DEFORM-2D FE code was used to simulate the effect of welding variables in friction welding process on the distributions of the state variables such as strain, strain rate and temperature. The formation of the metal burr during the friction welding process was successfully simulated, and the temperature distribution in the heat-affected zone indicated a good agreement with the variation of the microstructures in the HAZ.

scholarly journals Effect of friction welding conditions on tensile strength and hardness of AISI 310 stainless steel joints

2018 ◽  
Vol 204 ◽  
pp. 06004 ◽  
Author(s):  
Muhammad Iswar ◽  
Rusdi Nur
Keyword(s):  
Tensile Strength ◽  
Stainless Steel ◽  
Friction Welding ◽  
Rotational Speed ◽  
Welding Process ◽  
Raw Material ◽  
Welding Temperature ◽  
Lathe Machine ◽  
Joint Section ◽  
Steel Joints

This study aims to determine the effect of rotational speed and forging time on tensile strength and hardness through the friction welding process of stainless steel AISI 310. The research was carried out by friction welding process by using the lathe machine with varying rotational speed (550, 1020 and 1800 rpm), forging time (25, 35, 45 seconds), and welding temperature of 1050°C ± 10°. Axial pressure was obtained through the addition of a hydraulic system to the release head of a lathe machine with a forging pressure of 123.8 N/mm2. Furthermore, the friction welding results were tested mechanically by conducting the tensile and hardness tests. The experimental results showed that the highest tensile strength of the friction welding result of 706,61 N/mm2 was obtained at 1800 rpm and 45 seconds, and this value is lower when compared with raw material (780,25 N/mm2). The highest hardness value (61.5 HRC-A) was located on the welded joint section with 550 rpm of rotational speed and 25 seconds of forging time. The hardness of the parent metal is 69.45 HRC-A. The rotational variation influences the hardness value, the higher the rotational speed will increase the hardness. The longer of forging time will decrease the hardness.

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