Analysis of the Influence of Continuous-Drive Friction Welding on the Microstructure and Mechanical Properties of the UNS C64200 Bronze-Aluminum-Silicon Alloy

2021 ◽  
Vol 412 ◽  
pp. 185-195
Author(s):  
P.S.P. Monteiro ◽  
Givanildo Alves dos Santos ◽  
Francisco Yastami Nakamoto ◽  
Mauricio S. Nascimento ◽  
Rogerio Teram ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Welding ◽  
Base Material ◽  
Welding Process ◽  
Hardness Test ◽  
Temperature Characteristic ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Aluminum Silicon Alloy ◽  
Aluminum Silicon

Friction welding (FRW) is an important commercial solid-state welding process in which coalescence is achieved by frictional heat combined with pressure. The objective of this work is to analyze the microstructure and the mechanical behavior of the copper alloy UNS C64200 – bronze-aluminum-silicon, as well as to raise the ideal welding parameters so that there is adequate weldability after process of continuous-drive friction welding. Regarding the analysis of the microstructure, scanning electron microscopy was used to characterize phases. The mechanical properties were evaluated by means of a hardness test of the center of the welded joint, traversing the entire extent of the thermally affected zone. Results show that the UNS C64200 alloy, when subjected to conventional friction welding, behaves satisfactorily in terms of weldability, without the appearance of cracks or defects arising from the temperature characteristic of this process, as well as good hardness with values above the minimum established in norm and higher than the base material.

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.

Tensile Strength Characteristic of Al6061-T6 and Al7003-T6 Aluminum by the Change in the Friction Welding Process Variable

2014 ◽  
Vol 532 ◽  
pp. 534-539
Author(s):  
Hyun Sik Kim ◽  
Dong Pyo Hong ◽  
Sung Mo Yang ◽  
Hee Yong Kang
Keyword(s):  
Tensile Strength ◽  
Friction Welding ◽  
Welding Process ◽  
Hardness Test ◽  
Process Variable ◽  
Frictional Heat ◽  
Process Time ◽  
Pure Material ◽  
Aluminum Specimen ◽  
Welding Part

Recently, the various welding methods are used in the coupling method of product for the streamlining of complex products, simplification of manufacturing process, and decreasing process time a variety of industries. In this welding area, the friction welding technique has many advantages such as the mass production of rapid and highly reliable product and eases of automation, reduction of process time etc. so the domestic/external many studies are conducting. In this study, the Spindle speed, Up-set pressure as the necessary process variables for friction welding were change variously by using the round bar specimen of Al6061-T6 and Al7003-T6 Aluminum material, so the friction welding performance of the specimen by each change was compared and analyzed. In order to comprehend the friction welding performance, the frictional pressure was fixed with 20MPa, the spindle velocity was changed with 1,000, 1,500, 2,200rpm, and the Up-set pressure was changed with 35, 50, 65MPa for producing, so the performance by the specimen was compared and analyzed through the final tensile strength test. In addition, the effects of the friction welding on the specimen were examined through the analysis on the welding part hardness of the each friction welded aluminum specimen. In the result of the study, it showed the highest welding characteristic with the tensile strength 250.5MPa by applying 1,000rpm spindle velocity, 50MPa Up-set pressure compared to the lowest tensile strength 171.6MPa. In addition, as the result of hardness test, the hardness of specimen after conducting the friction welding of specimen decreased compared to the hardness of the pure material in the welding boundary, so it is judged that the measure to minimize the effects of the frictional heat by minimizing the friction welding time is needed.

Effect of Tool Parameters on Mechanical Properties of Friction Stir Welded Aluminum Alloy

2015 ◽  
Vol 786 ◽  
pp. 111-115 ◽  
Author(s):  
Srinivasa Rao Pedapati ◽  
G. Vimalan ◽  
Mokhtar Awang ◽  
A.M.A. Rani
Keyword(s):  
Mechanical Properties ◽  
Rotational Speed ◽  
Base Material ◽  
Hardness Test ◽  
Tensile Tests ◽  
Tool Geometry ◽  
Welding Parameters ◽  
Material Strength ◽  
Friction Stir ◽  
Tool Profiles

The mechanical properties of weld joints in Friction Stir Welding (FSW) are influenced by the welding parameters such as rotational speed, tool geometry and welding speed. In the present study, three different tool profiles have been used to weld the joints with three different rotational speed and two welding speeds. Full factorial experiments have been conducted using DoE. The mechanical properties of weld joint were evaluated by means of tensile tests and hardness test at room temperature. The experiment result shows that the average highest number of hardness was 40.06 HRB with square tool at a rotational speed of 2000rpm while lowest hardness was 30.84 HRB with cylindrical threaded tool at rotational speed of 1800rpm. The maximum tensile strength of the joint obtained is 265 M Pa which is close to base material strength. It is observed from experimental results that joints made by square tool yield more strength compared to other tool profiles.

Feasibility study of welding dissimilar Advanced and Ultra High Strength Steels

2020 ◽  
Vol 59 (1) ◽  
pp. 54-66
Author(s):  
Francois Njock Bayock ◽  
Paul Kah ◽  
Antti Salminen ◽  
Mvola Belinga ◽  
Xiaochen Yang
Keyword(s):  
Heat Input ◽  
High Strength Steel ◽  
Gas Metal Arc Welding ◽  
Base Material ◽  
Welding Process ◽  
High Strength Steels ◽  
High Strength ◽  
Hardness Test ◽  
Welding Parameter ◽  
Welding Parameters

AbstractThis study concerns the weldability of dissimilar Ultra high-strength steel (UHSS) and advanced high-strength steel (AHSS), which is used in the modern machine industry. The materials offered superior strength as well as relatively low weight, which reduces microstructure contamination during a live cycle. The choice of the welding process base of the base material (BM) and welding parameters is essential to improve the weld joint quality. S700MC/S960QC was welded using a gas metal arc welding (GMAW) process and overmatched filler wire, which was performed using three heat input (7, 10, and 15 kJ/cm). The weld samples were characterized by a Vickers-hardness test, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). The test reveals a decrease of softening areas in the HAZ and the formation of the stable formation of Bainite-Ferrite for S700MC and Bainite-martensite for S960QC when the heat input of 10 kJ/cm is used. It is recommended to use the GMAW process and Laser welding (Laser beam-MIG), with an optimal welding parameter, which will be achieved a high quality of manufacturing products.

scholarly journals Interlayer Effect on Connection of Mild Steel ST37 and Stainless Steel 201 on Rotary Friction Welding

2021 ◽  
Vol 65 (1) ◽  
pp. 23-30
Author(s):  
Yohanes Yohanes ◽  
◽  
Muhammad Heriansyah ◽  
Keyword(s):  
Stainless Steel ◽  
Mild Steel ◽  
Tensile Test ◽  
Friction Welding ◽  
Solid Phase ◽  
Welding Process ◽  
Hardness Test ◽  
Welding Parameters ◽  
Test Results ◽  
Rotary Friction Welding

Friction welding is a type of solid state welding where the welding process is carried out in a solid phase to combine various types of ferrous and non-ferrous metals that cannot be welded by the fusion welding method but for welding different metals the welding results are less than optimal due to cracks on the surface of the welding results and differences in mechanical properties that cause the welding result to be brittle, therefore an interlayer is used. In this study, observations were made on the process and results of the joint friction welding using dissimilar metal material between mild steel ST37 and stainless steel 201 with copper interlayer. The results of the test will be a tensile test to see the maximum tensile strength and a hardness test to see the hardness value of the interlayer variation of 0.3 mm, 0.5 mm, 1 mm and without an interlayer. The conclusions obtained are: (1) The effect of the addition of an interlayer on the rotary friction welding process includes the friction phase, the forging phase and the results of welding parameters in the form of motor power, motor angular speed, the change in specimen length is greater without using an interlayer compared to using an interlayer while the duration of welding time is greater using an interlayer than without using an interlayer. (2) The maximum tensile test results were obtained at the 1 mm interlayer at 482.43 MPa and the maximum hardness test results obtained at the 1 mm interlayer were 321.34 VHN.

Dissimilar Study on Friction Welding of AA 2025 Tube Plate to Copper Tube Using an External Tool

2016 ◽  
Vol 852 ◽  
pp. 362-368
Author(s):  
G. Gokul ◽  
S. Senthil Kumaran
Keyword(s):  
Plastic Deformation ◽  
Solid State ◽  
Friction Welding ◽  
Rotation Speed ◽  
Welding Process ◽  
Copper Tube ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Work Piece ◽  
Tube Plate

In this project the feasibility of friction welding in tube to tube plate using an external tool (FWTPET) of commercial Copper and Aluminum 2025 tube plate is investigated using an clearance fit method and the process parameters have been prioritized using Taguchi’s L27 orthogonal array. Than experiment is conducted and take results are compressive strength and hardness testing, Radiography test, Scanning Electron Microscopy and Energy Dispersive Spectroscopy testing. Aluminum 2025 are widely used in aerospace, automotive, marine, defense, construction etc. Friction welding is preferred for joining these materials as it is a solid state forge welding process and problems related with welding of aluminum tube plate and copper tube can be subdued through this process. This welding process is a solid state welding procedure that uses a non-consumable rotating tool that is permitted to rub against the work piece hence generating frictional heat. When the weld constraints such as tool rotation speed, welding time, axial load are optimum the friction between the work piece and the tool generates enough heat to create a plastic deformation layer at the weld interface. The process doesn’t involve any melting process and whole process occurs in solid state through plastic deformation and mass flow among the work pieces. The experimental investigation of FWTPET is done by varying the friction welding parameters such as work piece rotation speed, depth and projection. The work piece is rotated at the speeds 285 rpm, 480 rpm and 750rpm, projection 0 mm,1 mm,2 mm and depth are0.5 mm,1 mm,1.5 mm.The experiment is done in a general purpose vertical milling machine. To hold the work piece a fixture is designed. A tool is also designed. This work confirms that a high quality tube to tube plate joint can be achieved using FWTPET process.

scholarly journals ANALISA KEKUATAN TARIK PADUAN ALUMINIUM DENGAN SILIKON PADA DUDUKAN SHOCKBREAKER UKURAN 70 X 30 X 30 mm

2018 ◽  
Vol 3 (1) ◽  
Author(s):  
Risalah Zakaria
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Experimental Method ◽  
Base Material ◽  
Additional Component ◽  
Silicon Alloys ◽  
Silicon Alloy ◽  
Aluminum Silicon Alloy ◽  
Aluminum Base ◽  
Aluminum Silicon

ABSTRAKDudukan shockbreaker adalah komponen tambahan pada kendaran yang berfungsi sebagai peninggi agar sesuai dengan postur tubuh atau sesuai keinginan dari pengguna. Dudukan shockbreaker di buat dari bahan dasar aluminium yang dipadukan dengan paduan lainnya guna memperbaiki sifat mekanik aluminium. Sehingga perlu dilakukan penelitia menggunakan metode eksperimen ada paduan Aluminium-Silikon. Tujuan dari penelitian ini adalah untuk mengetahui kekuatan tarik dan nilai regangan pada coran aluminium dengan silikon pada dudukan Shockbreaker dengan variasi penambahan silikon 5%, 10%, dan 15%. Hasil penelitian ini menunjukan kekuatan tarik dan regangan yang diperoleh dari paduan silikon 5% adalah 91.64 MPa dan 0.0035%. Sedangkan kekuatan tarik dan regangan yang diperoleh dari paduan silikon 10% adalah 109.06 MPa dan 0.0038%. Sedangkan kekuatan tarik dan regangan yang diperoleh dari paduan silikon 15% adalah 135.56 MPa dan 0.0049%. Hasil yang terbaik dari aluminium paduan silikon dengan penambahan silikon 15% didapat kekuatan tarik adalah 135.56 MPa dan nilai regangan 0.0049%.Kata kunci : Aluminium, Silikon, Kekuatan Tarik, Regangan, ShockbreakerABSTRACTShockbreaker holder is an additional component in the vehicle that serves as enhancer to fit the posture or as desired from the user. Shockbreaker stands are made from aluminum base material combined with other alloys to improve the mechanical properties of aluminum. So it is necessary to do research using experimental method there is Aluminum-Silicon alloy. The purpose of this research is to know the tensile strength and strain value on aluminium castings with silicon on shockbreaker stand with variation of silicon 5%, 10%, and 15%. The results of this study showed that tensile strength and strain obtained from 5% silicon alloys were 91.64 MPa and 0.0035%. While the tensile strength and strain obtained from 10% silicon alloys were 109.06 MPa and 0.0038%. While the tensile strenght and strain obtained from 15% silicon alloys are 135.56 MPa and 0.0049%. The best result of aluminium silicon alloy with 15% addition of silicon obtained tensile strength is 135.56 MPa and strain value is 0.0049%.Keywords : aluminium, silicon, tensile strength, strain, Shockbreaker.

Effects of bottom plate in friction stir welding of AA6061-T6

2020 ◽  
Vol 118 (1) ◽  
pp. 108
Author(s):  
M.A. Vinayagamoorthi ◽  
M. Prince ◽  
S. Balasubramanian
Keyword(s):  
Mechanical Properties ◽  
Axial Load ◽  
Weld Zone ◽  
Welding Process ◽  
Bottom Plate ◽  
Welding Parameters ◽  
Nugget Zone ◽  
Friction Stir ◽  
Weld Joints ◽  
Fine Grain

The effects of 40 mm width bottom plates on the microstructural modifications and the mechanical properties of a 6 mm thick FSW AA6061-T6 joint have been investigated. The bottom plates are placed partially at the weld zone to absorb and dissipate heat during the welding process. An axial load of 5 to 7 kN, a rotational speed of 500 rpm, and a welding speed of 50 mm/min are employed as welding parameters. The size of the nugget zone (NZ) and heat-affected zone (HAZ) in the weld joints obtained from AISI 1040 steel bottom plate is more significant than that of weld joints obtained using copper bottom plate due to lower thermal conductivity of steel. Also, the weld joints obtained using copper bottom plate have fine grain microstructure due to the dynamic recrystallization. The friction stir welded joints obtained with copper bottom plate have exhibited higher ductility of 8.9% and higher tensile strength of 172 MPa as compared to the joints obtained using a steel bottom plate.

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