Microstructural Evaluation of Similar and Dissimilar Welding of Aluminum Metal Matrix Hybrid Composite by Friction Stir Welding

2020 ◽  
Vol 979 ◽  
pp. 124-128
Author(s):  
K. Sekar ◽  
P. Vasanthakumar
Keyword(s):  
Friction Stir Welding ◽  
Hybrid Composite ◽  
Metal Matrix ◽  
Hybrid Composites ◽  
Tool Material ◽  
Traverse Speed ◽  
Chromium Steel ◽  
Dissimilar Welding ◽  
Friction Stir ◽  
Aluminum Metal

To address the challenges of reducing the CO2 emission in automotives, Aluminum metal matrix hybrid composites have been extensively used in automotive and aerospace industries for the fabrication of light weight structure. Huge demand in joining dissimilar metals increased day by day, because it reduces the weight and cost of components by utilizing hybrid structures. The friction stir welding is adopted for dissimilar AA5754 rheo-squeeze cast (RSC) with AA7075 stir casted hybrid composite. Micro sized B4C and nanosized Al2O3 are reinforced into this material. Friction stir welding of these alloys by varying the tool material, pin and shoulder profiles, rotational speed, tool traverse speed and tilt angle. Microstructure of the joint are studied and inferences drawn are presented. The better welding was obtained with triangular and square pin profile when compared to cylindrical pin whereas triangular pin profile was more better than square pin. Tapered shoulder possessed greater strength, which resulted in a good weld in contrast to flat shoulder. The high carbon high chromium steel (HCHCr) tool exhibited a higher tool wear rate than stainless steel (SS) tool and found to be an appropriate one to weld aluminum hybrid composite.

scholarly journals Parametric Optimization of Friction Stir Welding Factors (FSWF) for Yellow Brass 405-20

2021 ◽  
Author(s):  
Syed Farhan Raza ◽  
Sarmad Ali Khan ◽  
Muhammad Salman Habib ◽  
Naveed Ahmed ◽  
Kashif Ishfaq ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Rotational Speed ◽  
Weld Zone ◽  
Tool Material ◽  
Traverse Speed ◽  
Weld Strength ◽  
Friction Stir Weld ◽  
Friction Stir ◽  
Wide Range ◽  
Percent Contribution

Abstract Friction stir welding (FSW) is a green, environmentally amicable, and solid-state joining technology. Industries are really interested in adopting FSW in its various applications e.g., automobile, aerospace, marine, construction, etc. FSW can successfully weld a wide range of materials (similar/dissimilar parent materials) including aluminum, copper, steel, different alloys from these materials, plastics, composites, and this material range is subjected to extension if FSW research efforts develop further in future. FSW of brass has already been accomplished by fewer researchers. In this research, yellow brass 405-20 is, therefore, welded with FSW that was never welded before. In this study, tool material utilized was M2 HSS that was also novel. Effect of two friction stir weld factors (FSWF), rotational speed (RS) and traverse speed (TS), was found on three output parameters i.e., weld temperature, weld strength and weld hardness. Weld temperature was found to be 63.72% of melting point of base metal. A significant improvement in friction stir weld strength (FSWS) was also measured that was found to be 82.78% of the base brass strength. Finally, weld hardness was measured which was found to be 87.80% of original brass hardness. Based on main effects of Anova Analysis, optimal FSW factors were found to be 1450 rpm and 60 mm/min resulting interestingly in maximum (max.)/optimal temperature, max./optimal weld strength, and minimum/optimal hardness. Rotational speed (RS) was found to be significant to affect the weld temperature only at the friction stir weld zone (FSWZ) with the highest percent contribution (PCR) of 65.69%. Transverse speed (TS) was found to be overall insignificant for affecting weld temperature, weld strength and hardness. However, PCR of transverse speed was found to be maximum for affecting weld strength as compared to its PCR towards both weld temperature and weld hardness. Error PCR was found to be the lowest for weld zone temperature, then for weld strength, and finally the highest for weld hardness. Interaction Plots (IPs) were also made for those FSWF which were found to be insignificant and to investigate any combined effect of FSWF on output parameters causing increased error PCR towards weld temperature, weld strength, and weld hardness.

The Extrinsic Influence of Tool Plunge Depth on Friction Stir Welding of an Aluminum Alloy

2011 ◽  
Vol 410 ◽  
pp. 206-215 ◽  
Author(s):  
K. Kandasamy ◽  
Satish V. Kailas ◽  
Tirumalai S. Srivatsan
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Rotation Speed ◽  
Tool Material ◽  
Traverse Speed ◽  
Test Machine ◽  
Plunge Depth ◽  
Friction Stir ◽  
Scientific Approach ◽  
Tool Rotation

The axial force during friction stir welding is sensitive to plunge depth of the tool and is one of the prime factors, which exercises control over heat generation during welding. Consequently, the plunge depth for a given tool rotation speed, traverse speed, material and test machine needs to be optimized so as to get a defect-free weld. In this paper, we present and briefly discuss the results of an elaborate and enriching investigation aimed at understanding the extrinsic influence of plunge depth of the tool on weld formation in aluminium alloy 7020-T6 for a range of rotation rate and traverse speed and using two different tools. The critical need for use of a scientific approach to optimize plunge depth for a given tool material and test machine in fewer number of steps is emphasized. Key Words: Friction Stir Welding, Tool Plunge, Rotation speed, Traverse speed, Aluminium Alloy 7020

Fusion and friction stir welding of aluminum-metal-matrix composites

2005 ◽  
Vol 36 (11) ◽  
pp. 3237-3247 ◽  
Author(s):  
D. Storjohann ◽  
O. M. Barabash ◽  
S. A. David ◽  
P. S. Sklad ◽  
E. E. Bloom ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Matrix Composites ◽  
Friction Stir ◽  
Aluminum Metal ◽  
Aluminum Metal Matrix Composites

scholarly journals An Evaluation of Optimal Friction Stir Welding Factors (FSWF) For Yellow Brass 405-20

2022 ◽  
Author(s):  
Syed Farhan Raza ◽  
Sarmad Ali Khan ◽  
Muhammad Salman Habib ◽  
Naveed Ahmed ◽  
Kashif Ishfaq ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Rotational Speed ◽  
Weld Zone ◽  
Tool Material ◽  
Traverse Speed ◽  
Microscopic Investigation ◽  
Weld Strength ◽  
Friction Stir Weld ◽  
Friction Stir ◽  
Wide Range

Abstract Friction stir welding (FSW) is a green, environmentally amicable, and solid-state joining technology. FSW can successfully weld a wide range of materials (similar/dissimilar parent materials) including aluminum, copper, steel, different alloys from these materials, plastics, composites. FSW of brass has already been accomplished by fewer researchers. In this research, yellow brass 405-20 is, therefore, welded with FSW that was never welded before. In this study, tool material utilized was M2 HSS that was also novel. Effect of two friction stir weld factors (FSWF), rotational speed (RS) and traverse speed (TS), was found on three output parameters i.e., weld temperature, weld strength and weld hardness. Weld temperature developed, was found to be 63.72% of melting point of base metal. A significant improvement in friction stir weld strength (FSWS) was also measured that was found to be 106.37% of the base brass strength. Finally, weld hardness was measured which was found to be 87.80% of original brass hardness. Based on main effects, optimal FSW factors were found to be 1450 rpm and 60 mm/min resulting interestingly in optimal temperature, optimal weld strength, and optimal hardness. Rotational speed (RS) was found to be significant to affect the weld temperature only at the friction stir weld zone (FSWZ) with the highest percent contribution (PCR) of 65.69%. However, PCR of transverse speed was found to be maximum for affecting weld strength as compared to its PCR towards both weld temperature and weld hardness. Current study was also deepened by microscopic investigation.

Dimensional analysis and a potential classification algorithm for prediction of wear in friction stir welding of metal matrix composites

2012 ◽  
Vol 226 (11) ◽  
pp. 2759-2769 ◽  
Author(s):  
Tracie Prater ◽  
Chase Cox ◽  
Brian Gibson ◽  
Alvin M Strauss ◽  
George E Cook
Keyword(s):  
Friction Stir Welding ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Dimensionless Parameter ◽  
Traverse Speed ◽  
Dimensionless Number ◽  
Matrix Composites ◽  
Friction Stir ◽  
Tool Condition ◽  
Major Process

The objective of this study is to develop a dimensionless parameter which can be used to estimate the amount of volumetric wear, a friction stir welding tool will experience in joining a metal matrix composite. Metal matrix composites are strong, lightweight materials consisting of a metal matrix (often an aluminum alloy) reinforced with ceramic particles or fibers. This study derives a dimensionless number based on three major process variables in friction stir welding: rotation speed, traverse speed, and length of weld. This number is correlated with wear data collected from experiments in which a steel friction stir welding tool was used to join Al 359/SiC/20p. The use of the dimensionless number as a classifier for tool condition is also evaluated.

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