Proceedings of First International Conference on Energy and Environment: Global Challenges March 09 & 10, 2018 Department of Chemical Engineering, National Institute of Technology Calicut, Kozhikode, Kerala, India.
Experimental Investigation of Friction Welding on Aluminium AA5083 Alloy Gurunath Shinde1,2*, Sarafaraj Mulani2,Pradip Gunavant2,Abhijeet Suryawanshi2 1
Research Scholar, Department of Mechanical Engineering, G.H.Raisoni College of Engineering & Management, Pune. Asst. Professor, Department of Mechanical Engineering, Dr.Daulatrao Aher College of Engineering, Karad, India
2
*Corresponding author email:
[email protected]
ABSTRACT In this paper effect of rotary friction welding on similar joints of aluminum AA5083 was investigated. Initially some trials were conducted with due consideration of material shrinkage. Successful joint was obtained when material shrinkage is less i.e. less material removal. Tensile strength and microstructure were further observed. All samples were failed at weld region except one which was failed at parent material showing tensile strength of weld is more than parent material. Keywords – Rotary Friction Welding, Tensile Strength, Microstructure. (CP-Al) and austenitic stainless steel (AISI 304).The joint, which had high joint efficiency, the fracture on the CP-Al side with no crack at the weld interface, and no IMC interlayer on the weld interface, could be successfully achieved. Liang et al [2] carried out study on 5A33 aluminum alloy bar with AZ31B magnesium alloy bar by continuous drive friction welding. The tensile strength of the joints increased with increasing friction time and on average the highest strength could reach up to 101 MPa when friction time was 5s.All the friction welded samples failed at the friction interface during tensile test. Shinde et al[3] have done review of friction welding on different materials and their weld ability. Successful weld joints are obtained at optimal parameter values. Improper weld parameters led to defects and failure of the joints. Some numerical approaches are also used to predict the process mathematically. Friction welding can be successfully applied to aluminum, mild steel, stainless steel, Cast Iron and some non metallic materials etc. Applications of friction welding are automotive, aerospace, defense, marine, refineries etc. Pandia Rajan et al [4] carried out to weld two dissimilar materials of SA 213 tube to SA 387 tube plate using an external tungsten carbide tool to enhance and validate the mechanical and metallurgical properties. It was observed that the optimal joint strength for the work piece without hole and with hole are 3062 MPa and 2845 MPa respectively. The value of Vickers hardness test was found in the welded zone to be much greater in work piece without hole that the work piece with hole are 313 Hv and 283 Hv respectively. Gavade et al [5] presented work deals
1. INTRODUCTION Friction welding is one of the solid-state welding processes which involve plunging one component relative to the other component by generating required amount of heat and then applying lateral force (upsetting force) to plastically displace and fuse materials. Friction welding is not actually a welding process in the traditional sense as no melting occurs, but it’s a forging technique (Fig.1). However, due to the similarities between these techniques and traditional welding, the term has become common. Friction welding does not require filler materials. Hence, the properties won’t be altered to a great extent and the weld doesn’t have any inclusions and gas porosity as compared to any other type of welding. Also, it is a very fast process because of which heat affected zone in the base metal is much less when compared to other welding processes. The weld obtained will also have greater strength than that of the other welding process. 100% metal to metal contact can be achieved using friction welding.
Fig.1.Basic Concept of Rotary Friction Welding (RFW)
2. LITERATURE REVIEW Kimura et al [1] described the effect of friction welding condition on joining phenomena, tensile strength, and bend ductility of friction welded joints between pure Al Conference Proceedings
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Gurunath Shinde et al., / ICEE 2018, March 09 & 10, 2018 with, effect of friction welding process parameters like friction pressure, friction time, and rotational speed on mechanical properties such as tensile strength, hardness and fatigue strength of aluminum 6061-T6 alloy. friction pressure and rotational speed are significantly contributing towards friction welding performance Therefore; most influencing parameters are friction pressure and rotational speed for optimizing mechanical properties. The second influencing parameter is friction time. Friction pressure, friction time and rotational speed have a significant effect on tensile strength, hardness and fatigue strength. Mechanical properties like tensile strength, fatigue strength and hardness of friction welded joints found less than base metal strength. Selvamani et al [6] conducted study on 12mm diameter AISI1035 grade steel rods with an aim to optimize the process parameters. The joints are made with various process parameter combinations subjected to tensile test. Rotational speed was found to have greater influence on tensile strength of the joints followed by Forging pressure and Friction pressure. The Vickers’s micro hardness of the weld zone has increased at 59.7% of the base metal.
Table 2: Physical Properties of AA5083
A. Material Selection: Rotary Fiction Welding was carried out on joints between similar Aluminum AA 5083 alloy. Dimensions used for AA5083 are 18 mm diameter and 70 mm long. The chemical composition of the base materials is presented in Table 1.Physical properties of the base materials are presented in Table 2.Fabrication Response of AA5083 is shown in table 3.
Eleme nt
Si
Fe
Cu
M n
Ni
Ti
Cr
Sn
Pb
% Pres
0.74
0.33
0.0 2
0.5 5
0.02 4
0.008 3
0.00 5
0. 07 8
0. 31
Ca
Di
Zr
V
CO
CD
PL
A L
0.0 003
0.0 02
0.0 009
0.0 06
0.0 005
0.0 01
0.0 002
97 .9
% Pres ence
Density
2650 kg/m3
Melting Point
570 °C
Modulus of Elasticity
72GPa
Electrical Resistivity
0.058 x 10Ω.m
Thermal Conductivity
121 W/mK
Thermal Expansion
25 x 10-6/k
Density
2650 kg/m3
Melting Point
570 °C
Modulus of Elasticity
72GPa
Electrical Resistivity
0.058 x 10Ω.m
Thermal Conductivity
121 W/mK
Thermal Expansion
25 x 10-6/k
B. Rotary Welding Set up: The 5 trials were initially carried out on continuous drive friction welding machine FWT T-12 machine. The round specimens of 18mm diameter and 70 mm long were prepared on simple lathe machine. During the welding process one specimen was kept stationery and other is rotated. The stationery specimen is then pushed towards rotating specimen with large axial force. Frictional heat causes softening of material and when other specimen is pushed both the specimen are attached together by formation of flash as shown in fig.2.
Table 1: Chemical Composition of AA5083
Elem ent
Value
Table 3: Fabrication Response of AA5083 Property Value
3. EXPERIMENTAL DETAILS
ence
Property
Fig.2.Stages of Rotary Friction Welding Conference Proceedings
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Gurunath Shinde et al., / ICEE 2018, March 09 & 10, 2018 C. Welding Conditions: Here we carried 5 trials of Similar Aluminum AA5083 Alloy. During the welding RPM, Friction Pressure, Feed, Upset Time, Friction Time and Shrinkage Range were kept constant. The experiments were carried out by changing the upset pressure (Kg/mm2).
4. RESULTS Five specimens are coded as D39, D40, D41, D42 and D43 as shown in Fig.4.Tensile Strength of all the 5 samples was carried out. All the samples were failed at the weld region as shown in fig.5 showing weld strength is poor than parent material while D41 piece is failed at the parent material showing strength of the weld is more than parent material.
Table 4. Experimental Details of welded joint Job
D39
D40
D41
D42
D43
RPM
1600
1600
1600
1600
1600
Feed
0.85
0.75
0.75
0.75
0.75
40
30
35
25
20
17
10
10
10
10
mm/min. Upset Pressure kg/mm2 Friction
Fig. No.5.Specimens after Tensile Test
Pressure Upset Time
3
3
3
3
3
Upset Delay
0.1
0.6
0.1
0.1
0.1
Break Delay
0.6
0.1
0.6
0.6
0.6
0.6
0.5
0.5
0.5
0.5
5.16
5.16
5.16
5.16
5.16
Friction
Sample D39 was failed at load of 88.9 kN and tensile strength of the weld is 316.88 N/mm2.Sample D40 was failed at load of 38.68 kN and tensile strength of the weld is 137.58 N/mm2.Sample D41 was failed at load of 96.3 kN and tensile strength of weld is 343.25 N/mm2.Sample D42 was failed at load of 87.92 kN and tensile strength of weld is 313.71 N/mm2.Sample of D41 of dimensions 18 X 10 mm was prepared for the micro structural analysis as shown in Fig.6. Microstructure of D41 was observed by scanned electron microscope (SEM) at 400X resolution as shown in fig.7.
Time Shrinkage Range
Fig.6.Cross Section of D41
Fig.4.Specimens after welding
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Gurunath Shinde et al., / ICEE 2018, March 09 & 10, 2018 [3] Shinde, G., Dabeer, P. “Review of Experimental Investigations in Friction Welding Technique”.Proceedings of the International Conference on Science & Engineering for Sustainable Development (2017), 373-384. doi:http://dx.doi.org/10.21013/jte.ICSESD201736 [4] S. Pandiarajan, S. Senthil umaran, L.A. Kumaraswamidhas, R. Saravanan, “Interfacial microstructure and optimization of friction welding by Taguchi and ANOVA method on SA 213 tube to SA 387 tube plate without backing block using an external tool” Journal of Alloys and Compounds 654 (2016) 534-545. [5] Jay Prakash Gavade, Dr. Prakash Ramdasi , “Experimental Investigation and stastical analysis of the Friction Welding Parameters for the aluminum Alloy 6061-T6 Using Factorial Design Of Experiment”. International Journal of Advanced Information in Arts, Science & Management (IJAIASM) (2014)Vol.1, No.2. [6]S.T. Selvamani, K. Palanikumar, “ Optimizing the friction welding parameters to attain maximum tensile strength in AISI 1035 grade carbon steel rods”, Measurement (2014)53:10–21
Fig.7.Microstructure of D41 Kellers Reagent etchant was used for surface preparation of cross section of D41 sample. Micro structural analysis shown particles of Mg2Si (Black) in matrix of aluminum solid solution.
5. CONCLUSION Rotary Fiction Welding was carried out on joints between similar Aluminum AA 5083 alloy. The 5 trials were initially carried out on continuous drive friction welding machine FWT T-12 machine. Sample D39 was failed at load of 88.9 kN and tensile strength of the weld is 316.88 N/mm2.Sample D40 was failed at load of 38.68 kN and tensile strength of the weld is 137.58 N/mm2.Sample D41 was failed at load of 96.3 kN and tensile strength of weld is 343.25 N/mm2.Sample D42 was failed at load of 87.92 kN and tensile strength of weld is 313.71 N/mm2.
[7]S.R.SundaraBharathi,
A. Razal Rose, V. Balasubramanian “Tensile Properties and Microstructural Characteristics of Friction Welded Similar Joints of Aluminum Alloys”, International Journal of Current Engineering and Technology, Vol. 5, No. 2, (April 2015). [8] Rama Rao, A.Kiran Kumar Yadav, G.Sai Krishna Prasad “Design and Fabrication of Rotary Friction Welding on Lathe Machine”, International Journal of Engineering Research and Applications (IJERA), ISSN: 2248-9622, NATIONAL CONFERENCE on Developments, Advances & Trends in Engineering Sciences (NCDATES- 09th & 10th January 2015).
ACKNOWLEDGEMENTS We are thankful to the Principal, Vice-principal and Management of AGTI’s Dr.Daultrao Aher College of Engineering, Karad for providing financial support to carry out the work.
REFERENCE [1] M. Kimuraa, K. Suzukib, M. Kusaka, K. Kaizu, “Effect of friction welding condition on joining phenomena, tensile strength, and bend ductility of friction welded joint between pure aluminum and AISI 304 stainless steel” Journal of Manufacturing Processes 25 (2017) 116–125. [2] Zhida Liang, Guoliang Qin, Peihao Geng, Fan Yang, Xiangmeng Meng “Continuous drive friction welding of 5A33 Al alloy to AZ31B Mg alloy” Journal of Manufacturing Processes 25 (2017) 153–162.
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