Effect of Rotational Speed on Static and Fatigue Properties of Rotary Friction Welded Dissimilar AA7075/AA5083 Aluminium Alloy Joints

In this work, rotary friction welding processes of dissimilar AA7075/AA5083 aluminium alloy rods with the diameter of 15 mm were performed at varying rotational speeds, typically 370 to 2500 rpm. The aim of this research is to improve mechanical properties, in particular, strength and fatigue performance of the weld joints. Several experiments including macro and microstructural examinations, Vickers microhardness measurements, tensile tests, fatigue tests and residual stress measurements were carried out. Results showed that at higher rotational speeds, typically 540 rpm or above, the dissimilar AA7075/AA5083 rotary friction weld joints revealed a static fracture in the AA5083 base metal side, indicating that the joint efficiency is more than 100%. It seemed that the best weld joint was achieved at the rotational speed of 1200 rpm, in which the friction heat was sufficient to form metallurgical bonding without causing excessive flash and burn-off. In such a condition, the fatigue strength of the weld joint was slightly higher than AA5083 base metal, but it was lower than AA7075 base metal. It was confirmed that the crack origin is observed at the interface followed by fatigue crack growth towards AA5083 side, and the growth of crack seemed to be controlled by microstructure and residual stress.

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

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.

Dissimilar Rotary Friction Welding of Inconel 718 to F22 Using Inconel 625 Interlayer

Dissimilar metal joining has always been a challenging task because of the metallurgical incompatibility and difference in melting points of alloys being joined. Diffusion and mixing of alloying elements from dissimilar base metals at the weld often cause unwanted metallurgical changes resulting in unsuccessful welds or underperformance of the weldment. Solid-state dissimilar friction welds of Inconel 718 and F22 were prepared in this study with an Inconel 625 interlayer to address the carbon enrichment of Inconel 718 during the welding. Defect-free rotary friction welds were produced in this study. Microstructural and mechanical properties investigation of the weldments and base metals was carried out, and results were analysed. Intermixing zone was observed at the weld interface due to the softening of the metal at the interface and rotatory motion during the welding. The high temperatures and the plastic deformation of the intermixing zone and thermo-mechanically affected zone (TMAZ) resulted in the grain refinement of the weld region. The highest hardness was observed at the Inconel 718/F22 weld interface due to the plastic strain and the carbon diffusion. The tensile specimens failed in the F22 base metal for the weld prepared with and without the Inconel 625 interlayer. Inconel 718/F22 welds exhibited lower toughness values compared to the Inconel 718/F22 welds prepared with Inconel 625 interlayer.

Characterization of ultrafine-grained copper joints acquired by rotary friction welding

Copper rods with ultrafine-grained microstructure, obtained by multi-turn ECAP processing, were subjected to Direct Drive Rotary Friction Welding using various processing parameters, such as rotational speed and pressure, which resulted in different energy and heat input. Even though friction welding is a high energy process, by a proper selection of processing parameters it was possible to maintain grain size at around 0.7 µm in the weld zone and preserve the UFG microstructure. These microstructural features translated into mechanical properties: the YS for those specimens was around 330 MPa. Processing parameters that resulted in a larger heat input caused an increase in grain size to around 2 µm; this, however, increased ductility and led to a uniform elongation exceeding 5%. Corrosion resistance in the stir zone increased, as was evident in the higher open circuit potential and higher corrosion potential in comparison with base material; the observed differences were about 50 mV. These changes can be explained by the higher fraction of HAGBs in the SZ.

Microstructure and Mechanical Property Correlation Between Rotary Friction Welded Nitinol–Nitinol Joints

In the present study, a rotary friction process was used to join nitinol in a similar welding combination. Macro- and microstructure characteristics of the weld zone were compared with adjacent zones and the base metal. The hardness and tensile properties of the joints were evaluated, and the results were discussed in relation to the weld microstructure. The weld macrostructure revealed a uniform flash around the circumference of the weld. The optical microstructure of the welded sample revealed fine recrystallized grains at the weld interface due to heavy deformation followed by dynamic recrystallization. The phase transformation behavior of the base metal and welded samples was studied by using a differential scanning calorimeter (DSC). The drift in phase transformation temperatures after rotary friction welding may be attributed to fine grain formation at the weld interface. Friction welded samples exhibited improved yield strength and hardness values compared to the base metal due to grain refinement at the weld interface.

An investigation on the effect of nanoparticle reinforcement and weld surface shape on bending behavior of rotary friction-welded high-density polyethylene

In this research, high-density polyethylene rods were joined together using rotary friction-welding. The effects of nanoparticle reinforcement and weld surface shape on the welded joint strength were investigated. To this aim, high-density polyethylene rods with a length of 50 mm and a diameter of 22 mm were machined, and three weld surface shapes, that is, flat, step, and conic shapes (on male and female counterparts), were created. The high-density polyethylene rods were rotary friction-welded with the addition of ZnO and SiO2 nanoparticles. The bending strength of rotary friction-welded rods was assessed by conduction of three-point bending tests. The results showed that both the weld surface shape and nanoparticles influence the bending strength of the welded joints. It was found that the step sample welds have higher bending strength (average bending depth and force of 6.27 mm and 2027.8 N, respectively). Furthermore, except for the case of flat samples, the addition of the reinforcement nanoparticles resulted in the improvement of the bending strength of the rotary friction-welded rods.

Exploration of Rotary Friction Welding Technique

Friction welding is a solid-state welding system which welds materials without authentic melting it. This study explores papers of different researchers on the friction welding method and it has been observed that the welding parameters like friction time; friction pressure, forge time and forge pressure highly affect properties of welded joints. The reason for this investigation is to exhort industry and the insightful world regarding advantages of revolving friction welding so the technique may be utilized in an ideal manner.