scholarly journals The Study of Male-Female Chamfer Angle Effect on Aluminum 6061 Forging at Rotary Friction Welding Process

2021 ◽  
Vol 65 (2) ◽  
pp. 61-67
Author(s):  
Anugra Fikri Azmi ◽  
◽  
Yohanes Yohanes ◽  
Ridwan Ridwan Abdurrahman ◽  
◽  
...  
Keyword(s):  
Experimental Study ◽  
Tensile Strength ◽  
Friction Welding ◽  
Welding Process ◽  
Specimen Length ◽  
Maximum Tensile Strength ◽  
A Value ◽  
Rotary Friction Welding ◽  
Angle Effect ◽  
Aluminum Material

This research aims to investigate male-female chamfer angle effect on forging pressure, specimen length and the maximum tensile strength in splicing 6061 aluminum material, which used the rotary friction welding process. This research employed the analytical method to determine the timing of forging pressure as an initial reference to conduct the experimental study for the specimens test. The specimens were tested by varying the male-female chamfer angle, namely 0°, 15°, 30°, 45°, 60°. The results test were obtained the longest application of forging pressure at the male-female chamfer angle of 60° and the fastest application of forging pressure at the male-female chamfer angle of 15°. The change in length of the specimen during the welding process for each variation of the male-female chamfer angle varies due to the friction time different. The largest change in length was at the male-female chamfer angle of 15° and the smallest change in length at the male-female chamfer angle of 60°. The maximum tensile strength was obtained at the variation of male-female chamfer angle of 60° with a value of 226.47 MPa.

Optimizing the Friction Welding Process Parameter to Obtain the Maximum Tensile Strength in AA 2024 Grade High Strength Aluminum Alloy Joints

2016 ◽  
Vol 25 ◽  
pp. 11-19 ◽  
Author(s):  
S.T. Selvamani ◽  
S. Divagar ◽  
M. Vigneshwar
Keyword(s):  
Tensile Strength ◽  
Friction Welding ◽  
Research Work ◽  
Welding Process ◽  
High Strength ◽  
Process Parameter ◽  
Design Matrix ◽  
Engineering Structures ◽  
Maximum Tensile Strength ◽  
Aa 2024

Aluminum alloys are widely used in engineering structures and components where light weight or corrosion resistance were required. Friction welding is classified as a solid-state welding process where metallic bonding is produced at temperatures lower than the melting point of the base metals. Friction time, friction pressure, forging time, forging pressure and rotation speed are the most important parameters in the friction welding process. The Response Surface Methodology (RSM) is used to optimize the process parameter and also useful in developing a proper approximation for the right functional relationship between independent variables and the response variable that may differentiate the nature of the joints. The empirical relationships are developed with the help of ANOVA design matrix to obtain the maximum tensile strength in the joints. The integrity of the joints are evaluated by Optical Microscopy (OM) and Energy Dispersive X-ray Analysis (EDAX) in this research work.

scholarly journals Predicting the Ultimate Tensile Strength of AISI 1045 steel and 2017-T4 aluminum alloy joints in a laser-assisted rotary friction welding process using Machine learning: a comparison with Response surface methodology

2021 ◽  
Author(s):  
Germán Omar Barrionuevo ◽  
José Luis Mullo ◽  
Jorge Andrés Ramos-Grez
Keyword(s):  
Machine Learning ◽  
Tensile Strength ◽  
Response Surface Methodology ◽  
Friction Welding ◽  
Welding Process ◽  
Gradient Boosting ◽  
Rotary Friction Welding ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Abstract Welding metal alloys with dissimilar melting points make conventional welding processes not feasible to be used. Friction welding, on the other hand, has proven to be a promising technology. However, obtaining the welded joint's mechanical properties with characteristics similar to the base materials remains a challenge. In the development of this work, several of the machine learning (ML) regressors (e.g., Gaussian process, decision tree, random forest, gradient boosting, and multi-layer perceptron) were evaluated for the prediction of the ultimate tensile strength (UTS) in joints of AISI 1045 steel and 2017-T4 aluminum alloy produced by rotary friction welding with laser assistance. A mixed design of experiments was employed to assess the effect of the rotation speed, friction pressure, and laser power over the UTS. Furthermore, the response surface methodology (RSM) was employed to determine an empirical equation for predicting the UTS, and contours maps determine the main interactions. A total of 48 specimens were employed to train the regressors; the 5-fold cross-validation methodology was used to find the algorithm with greater precision. The gradient boosting regressor (GBR) and Gaussian processes regressors present the highest precision with a less than 3% percentage error for the laser-assisted rotary friction welding process. The capability of the GBR exceeds the accuracy of the RSM with a coefficient of determination (R2) of 90.90 versus 83.24 %, respectively.

scholarly journals Microstructure and Mechanical Properties of Dissimilar Friction Welding Ti-6Al-4V Alloy to Nitinol

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 109
Author(s):  
Ateekh Ur Rehman ◽  
Nagumothu Kishore Babu ◽  
Mahesh Kumar Talari ◽  
Yusuf Siraj Usmani ◽  
Hisham Al-Khalefah
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Flow Stress ◽  
Intermetallic Compound ◽  
Ultimate Tensile Strength ◽  
Friction Welding ◽  
Welding Process ◽  
Weld Interface ◽  
Dissimilar Joints ◽  
Dissimilar Alloys

In the present study, a friction welding process was adopted to join dissimilar alloys of Ti-Al-4V to Nitinol. The effect of friction welding on the evolution of welded macro and microstructures and their hardnesses and tensile properties were studied and discussed in detail. The macrostructure of Ti-6Al-4V and Nitinol dissimilar joints revealed flash formation on the Ti-6Al-4V side due to a reduction in flow stress at high temperatures during friction welding. The optical microstructures revealed fine grains near the Ti-6Al-4V interface due to dynamic recrystallization and strain hardening effects. In contrast, the area nearer to the nitinol interface did not show any grain refinement. This study reveals that the formation of an intermetallic compound (Ti2Ni) at the weld interface resulted in poor ultimate tensile strength (UTS) and elongation values. All tensile specimens failed at the weld interface due to the formation of intermetallic compounds.

Influence of Rotary Friction Welding Parameters on Tensile Strength and Length of TMAZ of Dissimilar Welded Joints from 32G2 and 40KhN Steels

2021 ◽  
Vol 410 ◽  
pp. 299-305
Author(s):  
Artem S. Atamashkin ◽  
Elena Y. Priymak ◽  
Elena A. Kuzmina
Keyword(s):  
Tensile Strength ◽  
Base Metal ◽  
Process Parameters ◽  
Welded Joints ◽  
Friction Welding ◽  
Tensile Tests ◽  
Welding Parameters ◽  
Rotary Friction Welding ◽  
Study Results ◽  
Friction Pressure

In this work, pipe billets with a diameter of 73 mm and a wall thickness of 9 mm from steels 32G2 and 40KhN are friction welded with an aim to optimize the process parameters. The friction pressure, the forging pressure and the length of the fusion varied. After the implementation of various welding modes, tensile tests and metallographic studies were carried out. The optimal welding parameters have been established, which make it possible to obtain tensile strength at the level of the 32G2 base metal. The study results of the microstructure and SEM fractographs after the optimal welding mode are presented.

scholarly journals The Optimum Process Parameter of Dissimilar Metal AA6061 – AISI304 Continuous Drive Friction Welding

2020 ◽  
Vol 55 (2) ◽  
Author(s):  
Totok Suwanda ◽  
Rudy Soenoko ◽  
Yudy Surya Irawan ◽  
Moch. Agus Choiron
Keyword(s):  
Tensile Strength ◽  
Response Surface ◽  
Process Parameters ◽  
Friction Welding ◽  
Welding Parameters ◽  
Optimum Process ◽  
Dissimilar Metals ◽  
Maximum Tensile Strength ◽  
Friction Pressure ◽  
Welding Processes

This article explains the use of the response surface method to produce the optimum tensile strength for the joining of dissimilar metals with the continuous drive friction welding method. The joining of dissimilar metals is one of the biggest challenges in providing industrial applications. Continuous drive friction welding has been extensively used as one of the important solid-state welding processes. In this study, the optimization of the friction welding process parameters is established to achieve the maximum tensile strength in AA6061 and AISI304 dissimilar joints via the response surface methodology. The effect of continuous drive friction welding parameters, which are friction pressure, friction time, upset pressure, and upset time, are investigated using response surface analysis. The design matrix factors are set as 27 experiments based on Box-Behnken. The 3D surface and the contour is plotted for this model to accomplish the tensile strength optimization. The optimization model of the tensile strength was verified by conducting experiments on the optimum values of the parameters based on the experimental data results. It can be denoted that the optimum process parameters settings were friction pressure = 25 MPa, friction time = 6 seconds, upset pressure = 140 MPa, and upset time = 8 seconds, which would result in a maximum tensile strength of 228.57 MPa.

Study the effect of Nano Zro2 and Tio2 and rotation speed on friction behavior of rotary friction welding of HIPS and P.P

2021 ◽  
Author(s):  
Mohammad Afzali ◽  
Vahid Asghari
Keyword(s):  
Mechanical Properties ◽  
Friction Welding ◽  
High Speed ◽  
Welding Process ◽  
Melting Process ◽  
Numerical Control ◽  
Bending Test ◽  
Optimum Shape ◽  
Friction Behavior ◽  
Rotary Friction Welding

Abstract the purpose of this project was to introduce a way to improve the mechanical properties of welded dissimilar material, which gives benefits such as affordable, high speed, and suitable bond property. In this experimental project, the friction welding method has been applied, including combining parameters, such as numerical control (NC) machine including two different speeds, and three different cross-sections; including flat, cone, and step surfaces. When the welding process was done, samples were implemented and prepared via bending test of materials. the results have shown that, besides increasing the machining velocity, the surface friction increased, and so did the temperature. By considering the stated experimental facts, the melting temperature of composite materials has increased. This provides the possibility of having a better blend of nanomaterial compared to the base melted plastics. Thus, the result showed that, besides increasing the weight percentage (wt %) of Nanomaterials contents and machining velocity, the mechanical properties have increased on the welded area for all three types of samples. This enhancement is due to the better melting process on the welded area with attendance of various Nanoparticles contents. Also, the results showed that the shape of the welding area could play a significant role, and the results also change drastically where the shape changes. Optimum shape in the welding process has been dedicated to the step surface. The temperature causes the melting process, which is a significant factor in the friction welding process.

scholarly journals A Study on Rotary Friction Welding of Titanium Alloy (Ti6Al4V)

2019 ◽  
Vol 2019 ◽  
pp. 1-9 ◽  
Author(s):  
Ho Thi My Nu ◽  
Truyen The Le ◽  
Luu Phuong Minh ◽  
Nguyen Huu Loc
Keyword(s):  
Mechanical Properties ◽  
Titanium Alloys ◽  
Friction Welding ◽  
Base Material ◽  
Welding Process ◽  
High Strength ◽  
Fusion Welding ◽  
Experimental Results ◽  
Thermomechanical Model ◽  
Rotary Friction Welding

The selection of high-strength titanium alloys has an important role in increasing the performance of aerospace structures. Fabricated structures have a specific role in reducing the cost of these structures. However, conventional fusion welding of high-strength titanium alloys is generally conducive to poor mechanical properties. Friction welding is a potential method for intensifying the mechanical properties of suitable geometry components. In this paper, the rotary friction welding (RFW) method is used to study the feasibility of producing similar metal joints of high-strength titanium alloys. To predict the upset and temperature and identify the safe and suitable range of parameters, a thermomechanical model was developed. The upset predicted by the finite element simulations was compared with the upset obtained by the experimental results. The numerical results are consistent with the experimental results. Particularly, high upset rates due to generated power density and forging pressure overload that occurred during the welding process were investigated. The performances of the welded joints are evaluated by conducting microstructure studies and Vickers hardness at the joints. The titanium rotary friction welds achieve a higher tensile strength than the base material.

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