Thermal analysis of friction welding process in relation to the welding of YSZ-alumina composite and 6061 aluminum alloy

2012 ◽  
Vol 258 (20) ◽  
pp. 8264-8272 ◽  
Author(s):  
M.B. Uday ◽  
M.N. Ahmad Fauzi ◽  
H. Zuhailawati ◽  
A.B. Ismail
Keyword(s):  
Thermal Analysis ◽  
Aluminum Alloy ◽  
Friction Welding ◽  
Welding Process ◽  
6061 Aluminum Alloy ◽  
Alumina Composite

Effect of Deformation Behavior on the Grain Size of the 6061 Aluminum Alloy Joint with Alumina by Friction Welding

2011 ◽  
Vol 83 ◽  
pp. 97-103 ◽  
Author(s):  
M. B. Uday ◽  
Mohd Noor Ahmad Fauzi ◽  
Zuhailawati Hussain ◽  
A.B. Ismail
Keyword(s):  
Grain Size ◽  
Aluminum Alloy ◽  
Friction Welding ◽  
Deformation Behavior ◽  
Welding Process ◽  
Industrial Applications ◽  
Deformation Mechanisms ◽  
Al Alloy ◽  
Diffraction Profile ◽  
6061 Aluminum Alloy

Friction welding is widely used as a mass-production method in various industries. Joining of ceramic-metal is one of the most essential needs of many industrial applications. Experiments were performed to observe the deformation characteristics of 6061 aluminum alloy after joining with alumina using friction-welding process at different rotational speeds and to relate difference in grain size with differences in deformation behavior. In the present study, electron microscopy and X-ray diffraction profile analysis were used to study the effect of plastic deformation of interface material on the grain size of 6061 aluminum alloy when there is a joint with the ceramic. The effect of rotation speed and the degree of deformation appeared to be high on the 6061 Al alloy than on the ceramic part. Results showed different deformation mechanisms at different rotational speeds and confirmed unambiguously the change in crystalline grains as a result of deformation mechanisms.

scholarly journals Relationship between diameter of base material and heat input in friction welding of 6061 aluminum alloy.

2002 ◽  
Vol 52 (1) ◽  
pp. 7-11 ◽  
Author(s):  
Takeshi SAWAI ◽  
Koichi OGAWA ◽  
Hiroshi YAMAGUCHI ◽  
Hiizu OCHI ◽  
Yoshiaki YAMAMOTO ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Heat Input ◽  
Friction Welding ◽  
Base Material ◽  
6061 Aluminum Alloy

An alternative approach to thermal analysis using inverse problems in aluminum alloy welding

2017 ◽  
Vol 27 (3) ◽  
pp. 561-574 ◽  
Author(s):  
Elisan dos Santos Magalhaes ◽  
Cristiano Pedro da Silva ◽  
Ana Lúcia Fernandes Lima e Silva ◽  
Sandro Metrevelle Marcondes Lima e Silva
Keyword(s):  
Thermal Analysis ◽  
Heat Flux ◽  
Aluminum Alloy ◽  
Inverse Problems ◽  
Welding Process ◽  
Experimental Methodology ◽  
Function Technique ◽  
Content Type ◽  
Radiation Coefficient ◽  
Welding Processes

Purpose The purpose of this article is the determination of the temperature fields in a weld region has always been an obstacle to the improvement of welding processes. As an alternative, the use of inverse problems to determine the heat flux during the welding process allows an analysis of these processes. Design/methodology/approach This paper studies an alternative for the thermal analysis of the tungsten inert gas welding process on a 6,060 T5 aluminum alloy. For this purpose, a C++ code was developed, based on a transient three-dimensional heat transfer model. To estimate the amount of heat delivered to the plate, the specification function technique was used. Lab experiments were carried out to validate the methodology. A different experimental methodology is proposed to estimate the emissivity (radiation coefficient). Findings The maximum difference between experimental and numerical temperatures is lower than 5 per cent. The determined emissivity value for the aluminum 6,060 T5 presented a good agreement with literature values. The thermal fields were analyzed as function of the positive polarity. The specification function method proved to be an adequate tool for heat input estimation in welding analysis. Originality/value The proposed methodology proves to be a cheaper way to estimate the heat flux on the sample. The estimated power curves for the welding process are presented. The methodology to calculate the emissivity (radiation coefficient) was validated.

scholarly journals Increasing of the Mechanical Properties of Friction Stir Welded Joints of 6061 Aluminum Alloy by Introducing Alumina Particles

2017 ◽  
Vol 17 (2) ◽  
pp. 29-40 ◽  
Author(s):  
M. A. Tashkandi ◽  
J. A. Al-Jarrah ◽  
M. Ibrahim
Keyword(s):  
Aluminum Alloy ◽  
Base Metal ◽  
Welded Joints ◽  
Volume Fraction ◽  
Welding Process ◽  
Welding Zone ◽  
6061 Aluminum Alloy ◽  
Friction Stir ◽  
Alumina Particles ◽  
Welding Line

AbstractThe main aim of this investigation is to produce a welding joint of higher strength than that of base metals. Composite welded joints were produced by friction stir welding process. 6061 aluminum alloy was used as a base metal and alumina particles added to welding zone to form metal matrix composites. The volume fraction of alumina particles incorporated in this study were 2, 4, 6, 8 and 10 vol% were added on both sides of welding line. Also, the alumina particles were pre-mixed with magnesium particles prior being added to the welding zone. Magnesium particles were used to enhance the bonding between the alumina particles and the matrix of 6061 aluminum alloy. Friction stir welded joints containing alumina particles were successfully obtained and it was observed that the strength of these joints was better than that of base metal. Experimental results showed that incorporating volume fraction of alumina particles up to 6 vol% into the welding zone led to higher strength of the composite welded joints as compared to plain welded joints.

On the problem of tool destruction when obtaining fixed joints of thick-walled aluminum alloy blanks by friction welding with mixing

2021 ◽  
Vol 23 (3) ◽  
pp. 72-83
Author(s):  
Kirill Kalashnikov ◽  
◽  
Andrey Chumaevskii ◽  
Tatiana Kalashnikova ◽  
Aleksey Ivanov ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Friction Welding ◽  
Welding Process ◽  
High Strength ◽  
Heterogeneous Structure ◽  
Adhesive Interaction ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Electric Erosion

Introduction. Among the technologies for manufacturing rocket and aircraft bodies, marine vessels, and vehicles, currently, more and more attention is paid to the technology of friction stir welding (FSW). First of all, the use of this technology is necessary where it is required to produce fixed joints of high-strength aluminum alloys. In this case, special attention should be paid to welding thick-walled blanks, as fixed joints with a thickness of 30.0 mm or more are the target products in the rocket-space and aviation industries. At the same time, it is most prone to the formation of defects due to uneven heat distribution throughout the height of the blank. It can lead to a violation of the adhesive interaction between the weld metal and the tool and can even lead to a destruction of the welding tool. The purpose of this work is to reveal regularities of welding tool destruction depending on parameters of friction stir welding process of aluminum alloy AA5056 fixed joints with a thickness of 35.0 mm. Following research methods were used in the work: the obtaining of fixed joints was carried out by friction welding with mixing, the production of samples for research was carried out by electric erosion cutting, the study of samples was carried out using optical metallography methods. Results and discussion. As a result of performed studies, it is revealed that samples of aluminum alloy with a thickness of 35.0 mm have a heterogeneous structure through the height of weld. There are the tool shoulder effect zone and the pin effect zone, in which certain whirling of weld material caused by the presence of grooves on tool surface is distinctly distinguished. It is shown that the zone of shoulders effect is the most exposed to the formation of tunnel-type defects because of low loading force and high welding speeds. It is revealed that tool destruction occurs tangentially to the surface of the tool grooves due to the high tool load and high welding speeds.

scholarly journals Comparative in Mechanical Behavior of 6061 Aluminum Alloy Welded by Pulsed GMAW with Different Filler Metals and Heat Treatments

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4157 ◽  
Author(s):  
Isidro Guzmán ◽  
Everardo Granda ◽  
Jorge Acevedo ◽  
Antonia Martínez ◽  
Yuliana Dávila ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Weld Joint ◽  
Welding Process ◽  
Mechanical Resistance ◽  
6061 Aluminum Alloy ◽  
Β Phase ◽  
Welding Processes ◽  
Filler Metals

Precipitation hardening aluminum alloys are used in many industries due to their excellent mechanical properties, including good weldability. During a welding process, the tensile strength of the joint is critical to appropriately exploit the original properties of the material. The welding processes are still under study, and gas metal arc welding (GMAW) in pulsed metal-transfer configuration is one of the best choices to join these alloys. In this study, the welding of 6061 aluminum alloy by pulsed GMAW was performed under two heat treatment conditions and by using two filler metals, namely: ER 4043 (AlSi5) and ER 4553 (AlMg5Cr). A solubilization heat treatment T4 was used to dissolve the precipitates of β”- phase into the aluminum matrix from the original T6 heat treatment, leading in the formation of β-phase precipitates instead, which contributes to higher mechanical resistance. As a result, the T4 heat treatment improves the quality of the weld joint and increases the tensile strength in comparison to the T6 condition. The filler metal also plays an important role, and our results indicate that the use of ER 4043 produces stronger joints than ER 4553, but only under specific processing conditions, which include a moderate heat net flux. The latter is explained because Mg, Si and Cu are reported as precursors of the production of β”- phase due to heat input from the welding process and the redistribution of both: β” and β precipitates, causes a ductile intergranular fracture near the heat affected zone of the weld joint.

scholarly journals Effect of heat input on joint performance in 6061 aluminum alloy friction welding.

2000 ◽  
Vol 50 (10) ◽  
pp. 505-511 ◽  
Author(s):  
Takeshi SAWAI ◽  
Koichi OGAWA ◽  
Hiroshi YAMAGUCHI ◽  
Hiizu OCHI ◽  
Yoshiaki YAMAMOTO ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Heat Input ◽  
Friction Welding ◽  
Joint Performance ◽  
6061 Aluminum Alloy

Effect of Activating Flux on the A356 and 6061 Aluminum Alloy GMA Welds

2016 ◽  
Vol 835 ◽  
pp. 161-166 ◽  
Author(s):  
Hsuan Liang Lin ◽  
Wun Kai Wang
Keyword(s):  
Aluminum Alloy ◽  
Gma Welding ◽  
Welding Process ◽  
Hot Cracking ◽  
Bead Geometry ◽  
Weld Bead Geometry ◽  
6061 Aluminum Alloy ◽  
Activating Flux ◽  
Dissimilar Welds ◽  
Grey Relational

The objective of this study is to investigate the effects of activating fluxes on the weld bead geometry, hot cracking susceptibility and mechanical property of A356 and 6061 aluminum alloy dissimilar welds in the gas metal arc (GMA) welding process. In this activated GMA welding process, there were nine single-component fluxes used in the initial experiment to evaluate the penetration capability of butt-joint GMA welds. The grey relational analysis (GRA) was employed to obtain the better weld bead geometry of welds that were considered with multiple quality characteristics. Based on higher grey relational grade (GRG), four single-component fluxes were selected to create mixed-component flux in the next stage. The experimental results showed that the GMA welds coated with activating flux were provided with better geometry of dissimilar welds. The experimental procedure of activated GMA welding process not only produced a significant increase in tensile strength of welds, but also improved the hot cracking susceptibility of aluminum alloy welds.

scholarly journals NUMERICAL SIMULATION ON JOINING OF CERAMICS WITH METAL BY FRICTION WELDING TECHNIQUE

2013 ◽  
Vol 22 ◽  
pp. 190-195 ◽  
Author(s):  
N. RAJESH JESUDOSS HYNES ◽  
P. NAGARAJ ◽  
S. JOSHUA BASIL
Keyword(s):  
Numerical Simulation ◽  
Thermal Analysis ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Temperature Distribution ◽  
Friction Welding ◽  
Transient Liquid Phase ◽  
Sheet Thickness ◽  
Welding Process ◽  
Element Analysis

The joining of ceramic and metals can be done by different techniques such as ultrasonic joining, brazing, transient liquid phase diffusion bonding, and friction welding. Friction Welding is a solid state joining process that generates heat through mechanical friction between a moving workpiece and a stationary component. In this article, numerical simulation on thermal analysis of friction welded ceramic/metal joint has been carried out by using Finite Element Analysis (FEA) software. The finite element analysis helps in better understanding of the friction welding process of joining ceramics with metals and it is important to calculate temperature and stress fields during the welding process. Based on the obtained temperature distribution the graphs were plotted between the lengths of the joint corresponding to the temperatures. To increase the wettability, aluminium sheet was used as an interlayer. Hence, numerical simulation of friction welding process is done by varying the interlayer sheet thickness. Transient thermal analysis had been carried out for each cases and temperature distribution was studied. From the simulation studies, it is found that the increase in interlayer thickness reduces the heat affected zone and eventually improves the joint efficiency of alumina/aluminum alloy joints.

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