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Chapter 4 IMPROVEMENT OF FRICTION WELDED JOINT BY REVERSINGTHE PROGRESSION OF WELDING

4.1 INTRODUCTION The friction welding of dissimilar materials is more

complicated than similar materials due to difference in the physical, thermal, chemical and mechanical properties of base materials. The welding of dissimilar material combinations such Al 6061 - SS 304, Al 5052 SS 304, Pure Al SS 304, Al 6061 copper, Pure Al copper are very important for industry and some of these weld combinations are used in critical applications such as nuclear power plants, cryogenic applications, rocket fuel systems, aerospace transition joints, ignition assembly, electrical applications,

automotive, aerospace etc. The weld strength and its interface properties are extremely important. The failure of these welded parts may lead to huge losses. Therefore quality of weld is extremely important. In friction welding of dissimilar materials combinations such as Al 6061 - SS 304, Al 5052 SS 304, Pure Al SS 304, Al 6061 copper, pure Al copper, the weld strength and its interface properties are degraded due to following: Formation of intermetallic compounds and these compounds strongly depends on local temperature attained during the

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welding process and they are responsible for brittle failure of the components.

Unbond zone at the central portion (inner region) of weld interface (specially in combinations such as Al 6061-SS 304 and Al 5052-SS 304)

Presence of oxides layer at the weld interface

Non uniform heat generation across the weld interface due to difference in rotational speed. The rotational speed of inner region is less than outer region. Therefore heat generated in the inner region is less than outer region.

The insufficient plastic deformation of SS 304 can lead to incomplete destruction and removal of oxides films and other contaminations from the weld interface which in turn results in low weld strength.

High temperature increases the tendency of intermetallic compound formation. The thickness of intermetallic layer increases as temperature increases and it also affects the heat affected zone (HAZ). The width of HAZ increases as temperature increases. To overcome the above problems the progression of friction welding process is reversed. In regular friction welding process the

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development of friction weld starts from the outer periphery and it progresses to inner region which increases the severity of above problems. The welding process is improved by reversing the

progression of welding and this is achieved by designing a new joint geometry. The new joint geometry reverses the progress of friction welding from inner region to outer periphery. The comparison and detail explanation of the proposed new joint geometry and its influence are discussed in detail in subsequent sections. The designs of regular and new joint geometry are shown in Figure 4.1(a) and 4.1(b) respectively.

(a). Regular Joint Geometry

(b). New Joint Geometry

Figure 4.1 Friction weld Joint Geometry

The diameters of both regular and new joint geometry are considered as 25 mm. In order to understand the influence of new joint geometry on ferrous materials, similar investigation were done on weld

combination of SS316L and E8 which are not susceptible to intermetallic layer formation.

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4.2 KEY FEATURES OF NEW JOINT GEOMETRY AND FRICTION WELDING PROCESS The key feature of the new joint geometry is explained by using example of weld combination of Al 6061 to SS 304. The shape of new joint geometry design for Al 6061 is as shown in Figure 4.2 and the shape of new joint geometry for SS 304 is a flat face cylindrical rod. The new joint geometry of Al 6061 is categorized into three regions a) Initial flat contact region b) Taper cylindrical region c) Straight cylindrical region

Figure 4.2 Key features of new joint geometry 4.2.1 INITIAL FLAT CONTACT REGION The initial flat contact region is the area which first comes in contact with flat face of SS304. The machine senses the contact

between the two faces and the weld cycle is started. Due to very small contact area, the initial torque at the start of weld is very small. As

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soon as the Al 6061 comes in contact with SS 304 heat generation is initiated due to rotation of SS 304 against Al 6061 under the compressive pressure. As initial flat face first comes in contact with flat face of SS 304, it gets sufficient time for heating and for removing the oxides and other impurities from the central region of the weld joint. 4.2.2 TAPER CYLINDRICAL REGION After initial flat contact region comes in contact with flat face of SS304, the taper cylindrical region gradually comes in contact with flat face of SS 304 to generate more heat. The taper cylindrical shape of new joint geometry facilitates in removal of oxides and other unwanted impurities by formation of burrs due to wear of its surface. As the taper cylindrical region is deformed gradually with flat face of SS 304 thus helps in avoiding excessive heating at outer periphery of rod which helps in preventing or reducing the tendency of

intermetallic layer formation. 4.2.3 STRAIGHT CYLINDRICAL REGION After heating, plasticization and consumption of taper

cylindrical region, the straight cylindrical region comes in contact with SS 304. After small amount of heating, the rotation of SS 304 rod is stopped and the compressive force is increased (forging pressure) and maintained for small amount of time (forging time) to complete the weld.

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The important parameters are marked in Figure 4.3 and its relevant dimensions are mentioned in Table 4.1, which are selected after trying various values.

Figure 4.3 Dimension of new joint geometry

S.No. 1 2 3 4 5 6

Material Combination Al 6061 - SS 304 Al 5052 - SS 304 Al 6061 Copper Pure Al Copper Pure Al - SS 304 En8 - SS 316 L

L (mm) 50 / 100 50 / 100 50 / 100 50 / 100 50 / 100 50 / 100

L1 (mm) 3.5 3.5 3 3 3 3.5

D (mm) 25 25 25 25 25 16

D1 (mm) 5 5 5 5 5 5

Table 4.1 Material combinations and dimensions

4.3 EXPERIMENTAL SETUP AND PROCEDURE Al 6061 and SS 304 are welded with direct drive friction welding machine. Two joint geometries (Regular joint geometry and new joint

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geometry) are considered for investigation. New joint geometry is selected after trying for different values.

4.3.1 WELD PARAMETERS In friction welding weld parameters plays a very critical role. The weld interface properties, weld strength and material consumption during welding depends on weld parameters. The weld parameters for various combinations are given in Table 4.2 to Table 4.7.

S.No. 1 2 3 4 5

Weld Parameters RPM Friction Pressure (MPa) Friction Time (Sec) Forging Pressure (MPa) Forging Time (Sec) Constant weld parameter

Values 1400 70 1 140 6

S. No. 1 2 3 4 5

Weld Parameters RPM Friction Pressure (MPa) Friction Time (Sec) Forging Pressure (MPa) Forging Time (Sec) Constant weld parameter

Values 1400 39 1 160 6

1 2 3 4 5

Soft Friction Time (Sec) Soft Pressure (MPa) Brake Delay (Sec) Upset Delay (Sec) Feed (101mm\min)

0 0 0.6 0.1 101

1 2 3 4 5

Soft Friction Time (Sec) Soft Pressure (Mpa) Brake Delay (Sec) Upset Delay (Sec) Feed mm/min.

0 0 0.1 .6 101

Forging / Upset Condition - Before Breaking

Forging / Upset Condition After breaking

Table 4.2 Weld parameters for welding of Al 6061 SS 304

Table 4.3 Weld parameters for welding of Al 5052 SS 304

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S. No. 1 2 3 4 5

Weld Parameters RPM Friction Pressure (MPa) Friction Time (Sec.) Forging Pressure (MPa) Forging Time (Sec) Constant weld parameter

Values 1400 60 0.5 125 3

S. No. 1 2 3 4 5

Weld Parameters RPM Friction Pressure (MPa) Friction Time (Sec.) Forging Pressure (MPa) Forging Time (Sec) Constant weld parameter

Values 1400 65 0.5 125 4

1 2 3 4 5

Soft Friction Time (Sec) Soft Pressure (MPa) Brake Delay (Sec.) Upset Delay (Sec.) Feed (mm/min.)

1 30 0.3 0.1 101

1 2 3 4 5

Soft Friction Time (Sec) Soft Pressure (Sec.) Brake Delay (Sec.) Upset Delay (Sec.) Feed (mm/min.)

1 30 0.3 0.1 101

Forging / Upset Condition After Brake

Forging / Upset Condition After Brake

Table 4.4 Weld parameters for welding of pure Al SS 304

Table 4.5 Weld parameters for welding of Al 6061 Copper

S. No. 1 2 3 4 5

Weld Parameters RPM Friction Pressure (MPa) Friction Time (Sec.) Forging Pressure (MPa) Forging Time (Sec) Constant weld parameter Soft Friction Time (Sec) Soft Pressure (MPa) Brake Delay (Sec.) Upset Delay (Sec.) Feed (mm/min.)

Values 1400 60 0.5 115 3

S. No. 1 2 3 4 5

Weld Parameters RPM Friction Pressure (MPa) Friction Time (Sec.) Forging Pressure (MPa) Forging Time (Sec) Constant weld parameter

Values 1400 70 1 180 3

1 1 2

Soft Friction Time (Sec) Soft Pressure (MPa) Brake Delay (Sec.) Upset Delay (Sec.) Feed (mm/min.)

0 0 0.1 0.6 101

1 2 3 4 5

30 3 0.3 4 0.1 5 101 Forging / Upset Condition After Brake

Forging / Upset Condition After Brake

Table 4.6 Weld parameters for welding of Pure Al Copper

Table 4.7 Weld parameters for welding of En 8 SS 316

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4.4. RESULTS AND DISCUSSIONS 4.4.1 COMPARISION OF HEAT GENERATION PATTERN WITH REGULAR AND NEW JOINT GEOMETRY AND ITS EFFECT ON INTERFACE PROPERTIES The heat generation at weld interface plays a vital role in friction welding of Al alloys with stainless and Al alloys with copper as these materials has tendency to form intermetallic compounds at the weld interface which are undesirable and they are responsible for lowering the weld strength and brittle failure of the weld joint. The formation of intermetallic compound at the weld interface strongly depends on the local temperature attained during welding process. The generation of heat during the process of friction welding is determined by relative rotation speed, unit pressure, size of the cross section of the welded work piece and friction coefficient. The heat generation rate during friction phase can be calculated by [108]. qf = 2RNFn (4.1)

Where qf is heat generation rate during friction phase, is coefficient of friction, N is rotation speed of work piece, Fn is normal force applied on the work piece and R is the distance of the calculated point from the work piece axis. Heat generation due to plastic deformation qp is given as [108] qp= (4.2)

Where, is the inelastic heat fraction, is the effective stress and is the plastic strain.

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The heat generation pattern helps to understand the following. a) The evolution of welding across the cross section of work piece. b) The pattern of intermetallic compound formation and its growth during welding. c) The micro structural and microhardness changes and d) Weld integrity The above are discussed in detail in subsequent sections. The comparison of heat generation pattern for regular and new joint geometry is presented below. (i.e. in section 4.4.1.1 and 4.4.1.2) 4.4.1.1 CHARECTERIZATION OF HEAT GENERATION FOR REGULAR JOINT GEOMETRY AND ITS EFFECT ON WELD INTERFACE The heat generation pattern in regular joint geometry is shown in Figure 4.4. The pattern is calculated by Equation 4.1. This is in agreement with previous studies of Vill [29]. The heat generated at the outer region is more than inner region due to relatively lower speed at the inner region therefore the weld progresses from the outer periphery to inner region as shown in Figure 4.5. Due to insufficient heating in the inner region and progress of weld from outer periphery to inner region results in entrapment of oxides and other impurities at the central portion of weld interface. Because of insufficient heating and entrapment of oxides at the inner region results in formation of unbound zone at the central portion (inner region) of the weld interface as shown in Figure 4.6. The effect

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of unbond region with variation of cross section area is shown in Figure 4.7. The unbound zone can be prevented by increasing the

heating time but the increase in heating time leads to intermetallic compound formation at the weld interface as illustrated in Figure 4.8. The presence of unbound region is determined by three methods. First, by observing the tensile fractured weld interfaces of Al 6061 and SS 304 which was failed at weld joint. Small particles of Al 6061 are attached to outer region and absence of attached particles of Al 6061 on inner region of fractured surface as shown in Figure 4.9 which confirms that weld progresses from the outer region to inner region. In second method the diameter is reduced to half size and tensile test is conducted to evaluate the weld strength of inner region. It is observed that the weld strength is significantly reduced if the diameter is reduced to half. This also clearly indicates unbound zone in the inner region.

Figure 4.4 Heat generation pattern in regular joint geometry

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Figure 4.5 The progression of weld from outer periphery to inner region (Regular joint geometry)

Figure 4.6 Illustration of unbound zone (indicated by white box) (Regular joint geometry)

Figure 4.7 Effect of unbound zone with variation of cross section (Regular Joint Geometry)

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Figure 4.8 Increase in intermetallic layer thickness with Increase in heating time (Friction time) for Regular joint geometry

Figure 4.9 Fractured interface surface of regular joint geometry (small particles of Al 6061 are attached to outer periphery of SS 304)

In third method, the unbound zone was confirmed in fractograph of fractured surface (at weld) of Al 6061 copper as shown in Figure 4.10. The copper is welded only at the outer region leaving unbound zone in the inner region.

(Unbound zone)

Figure 4.10 Fractograph of tensile fractured Al6061-SS 304

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4.4.1.2 CHARECTERIZATION OF HEAT GENERATION FOR NEW JOINT GEOMETRY AND ITS EFFECT ON WELD INTERFACE The new joint geometry facilitates in initiating heat generation at inner region and it progresses to outer periphery therefore welding process follow the same path. The weld is started from the inner region and it propagates to outer region as shown in Figure 4.11. This helps in uniform heat generation across the cross section of the work piece and it also helps in removal of oxides and other impurities from the central portion of the weld interface. The same can be observed in the fractured tensile specimen as shown in Figure 4.12. It shows small amount of Al 6061 is attached at the inner region of the SS 304 specimen.

Figure 4.11 Weld progresses from inner region periphery to outer region (New joint geometry)

Figure 4.12 Fractured interface surface of new joint geometry specimen

4.4.2 DETERMINATION OF TENSILE STRENGTH FOR REGULAR AND NEW JOINT GEOMETRY The strength of weld joint is determined by tensile test. In order to determine the weld strength of the inner region (central portion of the weld), half size tensile specimen is considered. The dimensions of

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full size standard and half size tensile specimens are shown in Figure 4.13 and Figure 4.14 respectively. The tensile strength of new joint geometry is compared with regular joint geometry for Al 6061 - SS 304, Al 5052 SS 304, Pure Al SS 304, Pure Al to Copper and Al 6061 Copper.

Figure 4.13 Tensile full size specimen

Figure 4.14 Tensile half size specimen

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4.4.2.1 COMPARISION OF TENSILE STRENGTH FOR REGULAR AND NEW JOINT GEOMETRY The tensile strength of regular and new joint geometry for Al 6061-SS304, Al 5052-SS304, Pure Al-SS304, Al6061-Cu and Pure AlCu is given in Table 4.8, Table 4.9, Table 4.10, Table 4.11 and Table 4.12 respectively.

S.No. 1 2

Joint Geometry Regular Joint Geometry New Joint Geometry

Tensile Strength, MPa (Full size std specimen) 254 278.65

Tensile Strength, MPa (Half size specimen) 212 272.4

Table 4.8 Tensile strength of regular and new joint geometry for Al 6061 SS 304

Joint Geometry S.No 1 2 Regular Joint Geometry New Joint Geometry

Tensile Strength, MPa (Full size std specimen) 246.42 256.08

Tensile Strength, MPa (Half size specimen) 228.9 258.26

Table 4.9 Tensile strength of regular and new joint geometry for Al 5052 SS 304

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Tensile Strength, MPa (Full size std specimen) 86.52 105.28 Tensile Strength, MPa (Half size specimen) 82.1 102.57

S.No 1 2

Joint Geometry Regular Joint Geometry New Joint Geometry

Table 4.10 Tensile strength of regular and new joint geometry for Pure Al SS 304

S.No.

Joint Geometry

Tensile Strength, MPa ( Full size std specimen) 239.21 250.85

Tensile Strength, MPa (Half size specimen) 237.74 249.4

1 2

Regular Joint Geometry New Joint Geometry

Table 4.11 Tensile strength of regular and new joint geometry for Al 6061 Copper

S.No 1 2

Joint Geometry Regular Joint Geometry New Joint Geometry

Tensile Strength, MPa (Full size std specimen) 83.41 101.27

Tensile Strength, MPa (Half size specimen) 72.1 101.95

Table 4.12 Tensile strength of regular and new joint geometry for Pure Al Copper

The graphical representation of comparison of tensile strength of Al 6061-SS304, Al5052-SS304, PureAl-SS304, Al 6061-Cu and Pure Al-Cu are given in Figure 4.15, Figure 4.16, Figure 4.17, Figure 4.18 and Figure 4.19 respectively. In Figure 4.15, it can be observed

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that the tensile strength of Al 6061-SS304 with new joint geometry is 278.65 MPa where as tensile strength of regular joint geometry is 254 MPa. The tensile strength of new joint geometry is more than regular joint geometry. The tensile strength of parent Al 6061 is 269.24 MPa which was determined by tensile test to know the joint efficiency. Similarly, it was observed that the tensile strength of new joint geometry of Al 5052, SS304, Pure Al-SS304, Al 6061-Cu and Pure AlCu was more than regular joint geometry.

The tensile test specimen of pure Al SS 304 is shown in Figure 4.20. The tensile strength of weld is more than parent material. The specimen is fractured in parent material but not at the weld joint.

(a)

(b)

Figure 4.15 Comparison of tensile strength of Regular and new Joint Geometry for Al 6061 SS 304

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(a)

(b)

Figure 4.16 Comparison of tensile strength of Regular and new Joint Geometry for Al 5052 SS 304

Tensile Strength, MPa

(Half size specimen) 110 100 90 80 70 Regular Joint Geometry New Joint Geometry

Tensile Strength (Half size specimen)

(a)

(b)

Figure 4.17 Comparison of tensile strength of Regular and New Joint Geometry for Pure Al SS 304

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(a)

(b)

Figure 4.18 Comparison of tensile strength of Regular and New Joint Geometry for Al 6061 Copper

(a)

(b)

Figure 4.19 Comparison of tensile strength of Regular and New Joint Geometry for Pure Al Copper

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Figure 4.20 Tensile test specimen of SS 304 Pure Al (Fractured in parent material)

4.4.2.2 COMPARISION OF TENSILE STRENGTH OF STANDARD SIZE AND HALF SIZE TENSILE SPECIMENS FOR REGULAR AND NEW JOINT GEOMETRY TO EVALUATE WELD STRENGTH AT INNER REGION

In order to evaluate weld strength in inner region, the tensile strength of full size standards tensile specimen is compared with tensile strength of half size tensile specimen. The difference in tensile strength helps in evaluating weld strength at the inner region. For example, in Al 6061-SS304 as shown in Figure 4.21 the difference in tensile strength of standard specimen and half size specimen of regular joint geometry is 42 MPa (254 MPa minus 212 MPa), whereas the difference in tensile strength of standard specimen and half size specimen of new joint geometry is 6.25 MPa (278.65 MPa minus 272.4 MPa). This indicates the weld strength of the inner region of the regular joint geometry is inferior to new joint geometry.

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In new joint geometry, marginal difference is observed between the standards size and half size tensile specimen. This indicates that the weld strength of outer region and inner region are almost uniform. Similarly the comparison between weld strength for standard and half size tensile specimen for regular and new joint geometry are presented for Al 5052-SS305, Pure Al-SS304, Al6061-Cu and Pure AlCu in Figure 4.22, Figure 4.23, Figure 4.24 and Figure 4.25 respectively.

(a)

(b)

Figure 4.21 Comparison of tensile strength for standard size and half size tensile specimen with regular and new joint geometry For Al 6061 SS 304

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(a)

(b)

Figure 4.22 Comparison of tensile strength for standard size and half size tensile specimen with regular and new joint geometry for Al 5052 SS 304

(a)

(b)

Figure 4.23 Comparison of tensile strength for standard size and half size tensile specimen with regular and new joint geometry for Pure Al SS 304

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(a)

(b)

Figure 4.24 Comparison of tensile strength for standard size and half size tensile specimen with regular and new joint geometry for Al 6061 Copper

(a)

(b)

Figure 4.25 Comparison of tensile strength for standard size and half size tensile specimen with regular and new joint geometry for Pure Al Copper

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4.4.3

COMPARISON

OF

UPSET

(LOSS

OF

LENGTH)

FOR

REGULAR AND NEW JOINT GEOMETRY Upset plays a very important role in achieving good weld strength. The amount of upset required for particular material combination is very important and it is governed by weld parameters such as rpm, friction pressure, friction time, forging pressure and forging time.

Upset influences the weld strength, weld interface temperature, removal of oxides from interface and material consumption. Small amount of upset results in improper removal of oxides and it generally results in lower strength and large amount of upset results in more material consumption, high weld interface temperature. Therefore optimum upset is very important to achieve sound weld. The optimum upset depends on material properties of work pieces to be welded, size of work piece and surface condition.

The comparison of upset for regular joint geometry with new joint geometry at optimum weld parameters for Al 6061-SS304, Al 5052-SS304, Pure Al-SS304, Al 6061-Cu and Pure Al-Cu is given Table 4.13 and the graphical representation of the Al 6061-SS304, Al 5052-SS304, Pure Al-SS304 and Al 6061-Cu are given in Figure 4.26, Figure 4.27, Figure 4.28 and Figure 4.29 respectively.

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From the experimental result it is observed that the amount of upset observed in regular joint geometry is more than new joint geometry. Therefore the material consumption in regular joint geometry is more than new joint geometry. The more material consumption in regular joint geometry is due to two reasons. First, in regular joint geometry more material is in contact throughout the welding process and second, the difference in heat generation rate. The heat generation rate in the outer region is more than inner region. This is due to higher rotational speed in outer region when compared to inner region. In friction welding of Al alloys to SS 304 and copper, the deformation is unsymmetrical. Only Al alloy are deformed and there is no deformation in SS 304 and copper. This is due to differences in thermal, physical properties such as heat capacity, heat conductivity, hardness, melting points etc. In Al 6061-SS304, the amount of upset in regular joint geometry is more than new joint geometry. The loss of length in new joint geometry is only 7.5 mm, where as in regular joint geometry the loss of length is 13.4. The net material saving of 5.9 mm is achieved by using new joint geometry. Similarly the amount of material

consumption in the form of upset is more in regular joint than new joint geometry for welding of Al 5052-SS304, Pure Al-SS304, Al 6061SS304 and Pure Al-copper. Generally these materials are used as transition joints of 50 mm length. Here material saving by using new

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joint geometry results in 46% to 66% with higher strength when compared to friction welded joint with regular joint geometry. In weld combination of Al and its alloys to SS 304 and Al and its alloys to copper, only Al and its alloy is consumed. Al and its alloys are very costly therefore the new joint geometry helps in good amount of cost saving with better strength.

S.No

Materials

Joint Geometry Regular Joint Geometry

Upset 13.4 7.5 14.4 8.5 6.4 3 14.2 9.4 12 5.5

Al 6061-SS304 New Joint Geometry Regular Joint Geometry

Al 5052-SS304 New Joint Geometry Regular Joint Geometry

Pure Al-SS304 New Joint Geometry Regular Joint Geometry

Al 6061-Copper New Joint Geometry Regular Joint Geometry

Pure Al Copper New Joint Geometry

Table 4.13 Upset observed for regular and new joint geometry at optimum weld parameters

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Upset (Loss of length)

15 10 5 0 Regular Joint Geometry Upset New Joint Geometry 20 15 10 5 0

Upset (Loss of length)

Regular Joint Geometry Upset

New Joint Geometry

(Loss of length)

(Loss of length)

Figure 4.26 Comparison of Upset for Regular and New Joint Geometry for Al 6061 SS 304

Figure 4.27 Comparison of Upset for Regular and New Joint Geometry for Al 5052 SS 304

Upset (Loss of length)

7 6 5 4 3 2 1 0 Regular Joint Geometry Upset New Joint Geometry 15 10 5 0

Upset (Loss of length)

Regular Joint Geometry Upset

New Joint Geometry

(Loss of length)

(Loss of length)

Figure 4.28 Comparison of Upset for Regular and New Joint Geometry for Pure Al SS 304

Figure 4.29 Comparison of Upset for Regular and New Joint Geometry for Al 6061 Copper

4.4.4 COMPARISON OF WELD INTERFACE TEMPERATURE FOR REGULAR AND NEW JOINT GEOMETRY The weld interface temperature plays a very important role in friction welding of Al alloys to SS 304 and copper. These materials are susceptible to intermetallic layer formation. The formation of

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intermetallic compounds strongly depends on local temperature attained during welding process. The temperature attained during friction welding at optimum weld parameters for regular and new joint geometry for Al 6061SS304, Al 5052-SS 304, Pure Al-SS304 and Al 6061-Cu is given in Table 4.14. The graphical representation of the same results is shown in Figure 4.30, Figure 4.31, Figure 4.32 and Figure 4.33 respectively. The interface temperature developed in new joint geometry is less compared to regular joint geometry, which indicates reduction in heat affected zone. The tendency of intermetallic layer is reduced as welding is done at lower temperature.

S.No

Materials

Joint Geometry Regular Joint Geometry

Temperature (C) 384 208 283 212 158 138 359 267

Al 6061-SS304 New Joint Geometry Regular Joint Geometry

Al 5052-SS304 New Joint Geometry Regular Joint Geometry

Pure Al - SS304 New Joint Geometry Regular Joint Geometry

Al6061-Copper New Joint Geometry

Table 4.14 Temperature observed for regular and new joint geometry

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Temperature (C)
500 400 300 200 100 0 Regular Joint Geometry New Joint Geometry 300 250 200 150 100 50 0

Temperature (C)

Regular Joint Geometry

New Joint Geometry

Temperature (C)

Temperature (C)

Figure 4.30 Comparison of weld interface temperature for regular and new joint geometry for Al 6061 SS 304

Figure 4.31 Comparison of weld interface temperature for regular and new joint geometry for Al 5052 SS 304

Temperature (C)
160 155 150 145 140 135 130 125 Regular Joint Geometry New Joint Geometry 400 300 200 100 0

Temperature (C)

Regular Joint Geometry

New Joint Geometry

Temperature (C)

Temperature (C)

Figure 4.32 Comparison of weld interface temperature for regular and new joint geometry for Pure Al SS 304

Figure 4.33 Comparison of weld interface temperature for regular and new joint geometry for Al 6061 Copper

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4.4.5 COMPARISON OF BEND TEST FOR REGULAR AND NEW JOINT GEOMETRY Bend test is easy and very useful method for evaluating soundness of weld joint. It helps in revealing weld defects present in the weld joint. The bend test helps to determine weld properties such as ductility of weld zone, strength and crystalline structure of fractured surface. The brittle weld joint will fail at weld interface in bend test. The friction welded specimens of weld combinations Al 6061-SS 304, Al 5052-SS 304, Pure Al-SS 304, Al 6061-Copper and pure Al-copper with new joint geometry passed the bend test in 90 degrees bend. The bend test specimen of Pure Al-SS 304 is shown in Figure 4.34.

Figure 4.34 Bend test specimen of Pure Al - SS 304

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4.4.6 COMPARISON OF TENSILE STRENGTH FOR REGULAR AND NEW JOINT GEOMETRY FOR En 8 AND SS 316L

In order to understand the influence of joint geometry on ferrous materials, En8 and SS 316 L are welded with regular and taper joint geometry. The tensile strength values with new joint

geometry and regular joint geometry are given in Table 4.15.

Yield Joint Configuration Materials En8 - SS 316L En8 - SS 316L Regular Joint Geometry New Joint Geometry Strength Strength Ultimate Tensile

263.51 349.82

590.9 638.7

Table 4.15 The yield and ultimate tensile strength for En8-SS 316L The yield and ultimate tensile strength of new joint geometry is more than regular joint geometry. The heat affected zone in new joint geometry is less than regular joint geometry. The tensile test specimen of En8-SS 316L new joint geometry is shown in Figure 4.35 which has excellent strength and it is failed in parent material.

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Figure 4.35 Tensile specimen of En 8 SS 316L (New joint geometry failed in parent material)

4. 4.7 EFFECT OF FRICTION TIME ON WELD STRENGTH, UPSET AND WELD INTERFACE TEMPERATURE The variation of tensile strength with friction time is given in Figure 4.36. The tensile strength increases as friction time increases from 0.5 second to 1 second and beyond 1 second the tensile strength decreases. The decrease in tensile strength may be due to formation of intermetallic compounds.

300 Tensile Strength (Mpa) 250 200 150 100 50 0 0 1 2 3 4 New Joint Geometry Regular Joint Geometry

Friction Time (Seconds)

Figure 4.36 Effect of friction time on tensile Strength

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The upset and weld interface temperature increase as friction time increases as shown in Figure 4.37 and 4.38 respectively.

20 18 16 14 12 10 8 6 4 2 0 0 1 2 Friction Time (Seconds) 3 4

Upset (mm)

Upset

Figure 4.37 Effect of friction time on upset

350 300

Temperature C

250 200 150 100 50 0 0 1 2 3 4 Temperature

Friction Time (Seconds)

Figure 4.38 Effect of friction time on weld interface temperature

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4.4.8 POWER AND ENERGY IN FRICTION WELDING PROCESS

The analysis of power and energy in friction welding provides basic information for machine requirements, such as selection of spindle and design of the fixture for work holding. The power required for the friction welding can be expressed as P=T (4.3)

Where P is power required for friction welding, is angular velocity and T is torque. The Energy required for friction welding can be expressed as E=Pxt (4.4)

Where E is energy required for friction welding process and t is duration of friction welding. Most of the energy converts into heat and transfers to Al 6061 and SS 304. MESUREMENT OF RESPONSES USING DATA ACQUISITION SYSTEM The resultant variations of rpm, friction pressure, forging pressure, torque and consumption of parent material are observed using data acquisition system. The observations are given below: New joint geometry requires 7 % less energy for welding when compared to regular joint geometry. Lower capacity machine can be used for welding with new joint geometry when compared to regular joint geometry.