Synchrotron Energy-Dispersive X-Ray Diffraction Analysis of Residual Strains around Friction Welds between Dissimilar Aluminium and Nickel Alloys

2008 ◽  
Vol 571-572 ◽  
pp. 407-412 ◽  
Author(s):  
Tea Sung Jun ◽  
Shu Yan Zhang ◽  
Mina Golshan ◽  
Matthew J. Peel ◽  
David G. Richards ◽  
...  
Keyword(s):  
Friction Welding ◽  
Nickel Alloys ◽  
Dissimilar Materials ◽  
High Energy ◽  
Bond Line ◽  
Energy Dispersive ◽  
Mapping Technique ◽  
Friction Stir ◽  
Residual Strains ◽  
Welding Processes

Friction welding processes, such as friction stir welding (FSW) and inertia friction welding (IFW) are popular candidate procedures for joining engineering materials (including dissimilar pairs) for advanced applications. The advantages of friction welding include lack of large scale material melting, ability to join dissimilar materials, and relatively low propensity to introduce defects into the weld joint. For these reasons FSW and IFW have become the subjects of a number of studies aimed at optimising the joining operations to obtain improved joint strength and reduce distortion and residual stress. In the present study we used the diffraction of high energy polychromatic synchrotron X-rays to measure interplanar lattice spacings and deduce nominal elastic strains in friction stir welds between dissimilar aluminium alloys AA5083 and AA6082, and in coupons from inertia friction welds between dissimilar nickel-base superalloys IN718 and RR1000. Energy-dispersive diffraction profiles were collected by two detectors mounted in the horizontal and vertical diffraction planes, providing information about lattice strains in two nearly perpendicular directions lying almost in the plane of the plate samples mounted perpendicularly to the incident beam. Two-dimensional maps of residual stresses in friction-welded joints were constructed. Apart from the 2D mapping technique, the sin2ψ method (transmission) was also used in the case of inertia friction-welded joint between nickel alloys. Comparison between the two results allowed the variation of the lattice parameter with the distance from the bond line to be deduced. It was found that friction welding of two dissimilar materials with significant strength mismatch may lead to the creation of a region of compressive stress in the vicinity of the bond line, in contrast with the behaviour observed for joints between similar materials.

Friction-based welding processes: friction welding and friction stir welding

2020 ◽  
Vol 34 (24) ◽  
pp. 2613-2637 ◽  
Author(s):  
Dipen Kumar Rajak ◽  
Durgesh D. Pagar ◽  
Pradeep L. Menezes ◽  
Arameh Eyvazian
Keyword(s):  
Friction Stir Welding ◽  
Friction Welding ◽  
Friction Stir ◽  
Welding Processes

Various welding processes for joining aluminium alloy with steel: Effect of process parameters and observations–a review

2021 ◽  
pp. 095440622110596
Author(s):  
Sirakizhanthanallur Tamilselvan Selvamani
Keyword(s):  
Aluminium Alloy ◽  
Dissimilar Materials ◽  
Pressure Vessels ◽  
Cold Metal Transfer ◽  
Friction Stir ◽  
Automotive Engines ◽  
Metal Inert Gas Welding ◽  
Cold Metal Transfer Welding ◽  
Cold Metal ◽  
Welding Processes

The versatile aluminium alloys and steel are being used in automotive engines (exhaust systems), pressure vessels (flanges), turbine rotors, boilers (bonnet) and in many applications. The collective effect of these two metals created a revolution and are being utilized in most of the sectors wherein joining of these two dissimilar materials are always a major challenge faced by the manufacturers. Initially, the rivets were widely used for joining dissimilar materials owing to easy installation and flexibility, but the joint interlock fails and sudden ruptures occurred when exposed to higher load. Hence, numerous welding processes like metal inert gas welding, friction stir welding, friction stir spot welding, advanced laser welding, advanced cold metal transfer welding and hybrid welding techniques have been introduced in order to conquer the above problem because of residual stresses, cracks, distortion, and undercuts. Moreover, an appropriate standardization with controlled process inputs is still an uncertainty in joining the dissimilar materials. Hence, a detailed review on joining the dissimilar metals based on aluminium alloy and steel by various welding processes and influence of their parameters on the properties have been summarized in detail which would be a reference for manufacturing industries in the coming decades.

Friction Welding of Particle Reinforced Aluminium Based Composites

2011 ◽  
Vol 678 ◽  
pp. 85-93 ◽  
Author(s):  
Lorella Ceschini ◽  
Alessandro Morri ◽  
Fabio Rotundo
Keyword(s):  
Tensile Strength ◽  
Metal Matrix Composites ◽  
Friction Welding ◽  
Metal Matrix ◽  
Frictional Heating ◽  
Fusion Welding ◽  
Matrix Composites ◽  
Alloy Matrix ◽  
Friction Stir ◽  
Welding Processes

The widespread use of metal matrix composites (MMC) is often limited due to the difficulties related to their joining by means of traditional fusion welding processes. The aim of this work was to evaluate the effect on microstructure and mechanical properties (hardness and tensile strength) of two different friction welding techniques used for joining two Al-based metal matrix composites. In particular, Friction Stir Welding was applied to a 6061 (Al-Mg-Si) alloy matrix, reinforced with 20vol.% of Al2O3particles (W6A20A), while Linear Friction Welding was applied to a 2124 (Al-Cu-Mg) alloy matrix reinforced with 25vol.% of SiC particles (AMC225xe). Both the welding processes permitted to obtain substantially defect-free joints, whose microstructures was found to be dependent on both the initial microstructure of the composites and the welding processes. Hardness decrease was in the order of 40% for the FSW joint and of 10% for the LFW joint, mainly due to overaging of the matrix induced by the frictional heating, while the joint efficiency in respect to the ultimate tensile strength was 72% and 82%, respectively. Elongation to failure increased in the FSW joint due to coarsening of precipitates, whereas it decreased in the LFW joints due to the fibrosity in the thermomechanically altered zone. Fracture surface analysis showed good matrix/reinforcement interface for both composites.

scholarly journals Experimental Review on Friction Stir Welding of Aluminium Alloys with Nanoparticles

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 390
Author(s):  
Cyril Vimalraj ◽  
Paul Kah
Keyword(s):  
Friction Stir Welding ◽  
Dissimilar Materials ◽  
Strengthening Mechanism ◽  
High Heat ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Joint Properties ◽  
Weld Properties ◽  
Welding Processes

To reduce environmental impacts and ensure competitiveness, the fabrication and construction sectors focus on minimizing energy and material usage, which leads to design requirements for complex structures by joining of similar and dissimilar materials. Meeting these industrial demands requires compatible materials with improved properties such as good weight-to-strength ratios, where aluminum (Al) and its alloys are competing candidates for various complex applications. However, joining Al with fusion welding processes leads to joint deterioration. Friction stir welding (FSW) produces joints at temperatures below the melting temperature, thus avoiding flaws associated with high heat input, yet requires improvement in the resultant joint properties. Recent studies have shown that nanoparticle reinforcement in FSW joints can improve weld properties. The main focus of this study is to critically review similar and dissimilar friction stir welding of AA5083 and AA6082 with carbide and oxide nanoparticle reinforcement. The study also discusses the effect of welding parameters on reinforcement particles and the effect of nanoparticle reinforcement on weld microstructure and properties, as well as development trends using nanoparticles in FSW. Analysis shows that friction stir welding parameters have a significant influence on the dispersion of the reinforcement nanoparticles, which contributes to determining the joint properties. Moreover, the distributed nanoparticles aid in grain refinement and improve joint properties. The type, amount and size of reinforcement nanoparticles together with the welding parameters significantly influence the joint properties and microstructures in similar and dissimilar Al welds. However, research is still required to determine the strengthening mechanism used by nanoparticles and to assess other nanoparticle additions in FSW of Al alloys.

scholarly journals Depth Resolved Strain and Phase Mapping of Dissimilar Friction Stir Welds Using High Energy Synchrotron Radiation

2003 ◽  
Vol 35 (3-4) ◽  
pp. 145-152 ◽  
Author(s):  
R. V. Martins ◽  
V. Honkimäki
Keyword(s):  
Longitudinal Strain ◽  
Phase Distribution ◽  
Weld Zone ◽  
High Energy ◽  
Friction Stir Weld ◽  
Mapping Technique ◽  
Strain Component ◽  
Strain Mapping ◽  
Friction Stir ◽  
Phase Mapping

The strain and phase distribution in a dissimilar friction stir weld of AA6082-T6 to AA2024-T3 is investigated non-destructively. The measurements are performed using a novel depth resolved strain and phase mapping technique. The technique is based on the use of a focussed high energy synchrotron beam, a novel spiral slit system, and an area detector system. Through thickness measurements of the residual strain along the weld centre show strong variations with changes of sign. The strain scans across the weld exhibit a strong asymmetry in particular for the longitudinal strain component. A depth resolved strain mapping across the weld shows for the dominant longitudinal strain component variations in depth, especially on the AA6082 side of the weld. Results from the strain measurements are related to the depth resolved map of the material distribution in the weld zone.

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.

The Influence of Ultrasound Enhancement during Friction Stir Welding of Aluminum to Steel

2018 ◽  
Vol 767 ◽  
pp. 351-359 ◽  
Author(s):  
Marco Thomä ◽  
Guntram Wagner ◽  
Benjamin Straß ◽  
Bernd Wolter ◽  
Sigrid Benfer ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Dissimilar Materials ◽  
Dissimilar Joints ◽  
Power Ultrasound ◽  
Friction Stir ◽  
Wide Range ◽  
Steel Joints ◽  
Welding Processes ◽  
Ultrasound Enhancement

The innovative joining process of friction stir welding (FSW) offers a wide range of advantages for welding similar as well as dissimilar materials. Even for the field of poorly weldable material combinations like aluminum to steel with their strongly differing physical properties the method of FSW proved its capability for realizing dissimilar joints with tensile strengths up to more than 80 % of the aluminum base material. Trying to improve this value and other properties of the joints several approaches for hybrid friction stir welding processes were tested in the scientific community, whereas the ultrasound enhancement of FSW (USE-FSW) looked as one of the most promising reaching good results. To gain a deeper knowledge of the influence of the ultrasound on the friction stir welds different investigations were carried out in this paper. Therefore the method of USE-FSW was applied on two dissimilar aluminum/steel-joints with varying carbon content of the steel in this work. The material combinations AA6061/SAE1006 and AA6061/SAE1045 were welded successfully with and without additional power ultrasound. Afterwards a comparison between FSW-and USE-FSW-joints was carried out regarding the microstructure of the nugget and interface (IF) by light-microscopy as well as scanning electron microscopy. Furthermore the mechanical properties were characterized in a first step.

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>

scholarly journals Joining of dissimilar materials by friction stir welding

2018 ◽  
Vol 224 ◽  
pp. 01118 ◽  
Author(s):  
Zakaria Boumerzoug
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Physical Properties ◽  
Dissimilar Materials ◽  
Total Weight ◽  
Friction Stir ◽  
Pipe Welding ◽  
Race Cars ◽  
Welding Processes ◽  
Solid State Joining

Welding is a process of joining materials into one piece. Welding is used extensively for pipe welding, aerospace, aviation, biomedical implants, fabrication of race cars, choppers, etc. Welding processes include thermal fusion joining processes and solid-state joining processes. Among solid-state joining processes, there is a friction stir welding which is applied to join two workpieces without materials. This technique of welding has great is used to weld dissimilar materials. This type of welding is gaining renewed interest, because the main objective is to reduce the total weight and maintaining essential physical properties. The objective of this paper is to focus on the friction stir welding of dissimilar materials.

Trends in Joining Dissimilar Metals by Welding

2013 ◽  
Vol 440 ◽  
pp. 269-276 ◽  
Author(s):  
Paul Kah ◽  
Madan Shrestha ◽  
Jukka Martikainen
Keyword(s):  
Chemical Properties ◽  
Dissimilar Materials ◽  
High Energy ◽  
Industrial Applications ◽  
Fusion Welding ◽  
Dissimilar Metals ◽  
Energy Beam ◽  
Dissimilar Metal ◽  
Characteristic Features ◽  
Welding Processes

The welding of dissimilar materials finds a wide variety of applications in the fields of industrial construction and manufacturing, where the characteristic features of the different materials are optimized for the desired application to result in cost effectiveness and value addition. Non-fusion welding methods such as solid state welding and high energy beam welding are more popular for welding dissimilar metal combinations, due to fewer complications, than fusion welding, which melts the base metal and forms brittle intermetallic compounds (IMCs) that may lead to failure. Various factors have to be considered when assessing the feasibility of welding dissimilar metals and producing a sound weld joint. This paper presents a broad classification of the most commonly used welding processes for dissimilar materials, discusses some of the commonly used welding processes with examples of some common material combinations, critical factors for good welding, and practical difficulties arising from the physical and chemical properties of materials. From the findings, it can be inferred that continuous improvement and research is still required in the field of dissimilar metal welding, particularly in the light of increasing demand for tailored material for modern engineering and industrial applications.

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