Optimizing Linear Friction Welding Parameters to Attain Maximum Tensile Strength in Aluminum Alloy Joints

2018 ◽  
Vol 13 (2) ◽  
pp. 204-210
Author(s):  
P. Sivaraj ◽  
J. Ahamed Bahavudeen ◽  
V. Balasubramanian
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Welding ◽  
Welding Parameters ◽  
Linear Friction Welding ◽  
Maximum Tensile Strength ◽  
Linear Friction

scholarly journals The Optimum Process Parameter of Dissimilar Metal AA6061 – AISI304 Continuous Drive Friction Welding

2020 ◽  
Vol 55 (2) ◽  
Author(s):  
Totok Suwanda ◽  
Rudy Soenoko ◽  
Yudy Surya Irawan ◽  
Moch. Agus Choiron
Keyword(s):  
Tensile Strength ◽  
Response Surface ◽  
Process Parameters ◽  
Friction Welding ◽  
Welding Parameters ◽  
Optimum Process ◽  
Dissimilar Metals ◽  
Maximum Tensile Strength ◽  
Friction Pressure ◽  
Welding Processes

This article explains the use of the response surface method to produce the optimum tensile strength for the joining of dissimilar metals with the continuous drive friction welding method. The joining of dissimilar metals is one of the biggest challenges in providing industrial applications. Continuous drive friction welding has been extensively used as one of the important solid-state welding processes. In this study, the optimization of the friction welding process parameters is established to achieve the maximum tensile strength in AA6061 and AISI304 dissimilar joints via the response surface methodology. The effect of continuous drive friction welding parameters, which are friction pressure, friction time, upset pressure, and upset time, are investigated using response surface analysis. The design matrix factors are set as 27 experiments based on Box-Behnken. The 3D surface and the contour is plotted for this model to accomplish the tensile strength optimization. The optimization model of the tensile strength was verified by conducting experiments on the optimum values of the parameters based on the experimental data results. It can be denoted that the optimum process parameters settings were friction pressure = 25 MPa, friction time = 6 seconds, upset pressure = 140 MPa, and upset time = 8 seconds, which would result in a maximum tensile strength of 228.57 MPa.

Friction Welding of A 6061 Aluminum Alloy and S45C Carbon Steel

2004 ◽  
Vol 449-452 ◽  
pp. 437-440 ◽  
Author(s):  
Takeshi Shinoda ◽  
Shiniti Kawata
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Carbon Steel ◽  
Intermetallic Compound ◽  
Intermetallic Compounds ◽  
Friction Welding ◽  
Compound Layer ◽  
Weld Interface ◽  
Welding Parameters ◽  
Intermetallic Compound Layer

Many researches for friction welding of aluminum with either carbon steel or stainless steel have been carried out. From those results, it is concluded that the greatest problem is the formation of brittle intermetallic compounds at weld interface. However, it is not clearly demonstrated the effect of friction welding parameters on the formation of intermetallic compounds. This research purposes are to evaluate the formation of intermetallic compounds and to investigate the effect of friction welding parameters on the strength of welded joint. For these purposes, A6061 aluminum alloy and S45C carbon steel were used with a continuous drive vertical friction welding machine. Tensile test results revealed that the maximum tensile strength was achieved at extremely short friction time and high upset. The joint strength reached 92% of the tensile strength of A6061 base metal. Tensile strength of friction welding was increasing with increasing upset pressure when friction time 1sec. However, tensile properties were deteriorated with increasing friction time. It was observed that the amount of formed intermetallic compound was increasing with increasing friction time at weld interface. Partly formed intermetallic compound on weld interface were identified when friction time 1sec. However, intermetallic compound layer were severely developed with longer friction time at weld interface. It was concluded that intermetallic compound layer deteriorated the tensile properties of weld joints.

scholarly journals Optimization by RSM on rotary friction welding of AA1100 aluminum alloy and mild steel

2020 ◽  
Vol 11 (1) ◽  
pp. 34-42
Author(s):  
F. Khalfallah ◽  
Z. Boumerzoug ◽  
S. Rajakumar ◽  
E. Raouache
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Mild Steel ◽  
Friction Welding ◽  
Empirical Relationship ◽  
Dissimilar Materials ◽  
Welding Parameters ◽  
Pressure Time ◽  
Rotary Friction Welding ◽  
Aa1100 Aluminum Alloy

AbstractThe objective of this work is to investigate the rotary friction welding of AA1100 aluminum alloy with mild steel, and to optimize the welding parameters of these dissimilar materials, such as friction pressure/time, forging pressure/time and rotational speed. The optimization of the welding parameters was deduced by applying Response Surface Methodology (RSM). An empirical relationship was also applied to predict the welding parameters. Tensile test and micro-hardness measurements were used to determine the mechanical properties of the welded joints. Some joints were analyzed by scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) in order to investigate the formation of intermetallic compound (IMC) layer at the weld interface. Experimentally, the tensile strength of the weld increases with increasing the forging pressure/time, while the low level of forging pressure/time allows the formation of an IMC layer which reduces the tensile strength of the weld.

scholarly journals Optimization of Friction Welding Parameters to Maximize the Tensile Strength of Magnesium Alloy with Aluminum Alloy Dissimilar Joints Using Genetic Algorithm

Processes ◽  
2021 ◽  
Vol 9 (9) ◽  
pp. 1550
Author(s):  
Radosław Winiczenko ◽  
Andrzej Skibicki ◽  
Paweł Skoczylas
Keyword(s):  
Genetic Algorithm ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Magnesium Alloy ◽  
Friction Welding ◽  
Manufacturing Industry ◽  
Welding Parameters ◽  
Dissimilar Joints ◽  
Genetic Algorithm Method ◽  
Friction Joint

The friction rotary welding (FRW) of magnesium alloy to aluminum alloy was presented in a paper due to significant interest in the manufacturing industry. A genetic algorithm (GA) method for optimizing FRW process parameters of dissimilar light alloys was presented. After obtaining the welding parameters by GA method, it was possible to determine the best tensile strength of the friction joint. The obtained joints were subjected to tensile strength. The highest tensile strength TS = 178 MPa was found using a genetic algorithm for the following friction welding parameters: friction force FF = 16 kN, friction time FT = 4 s, and upsetting force UF = 44 kN. The optimized values were compared with the experimental results. The application of the genetic algorithm method allowed increasing the tensile strength joint from 88 to 180 MPa. The maximum tensile strength of the friction welded magnesium alloy-aluminum alloy joints was 73% of the base AZ31B metal. The relationship between welding parameters and strenght of welds was also demonstrated in this study.

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