FRICTION STIR WELDING

Chapter 1
Introduction
The assembly of wheel sets is done on a highly automated wheel assembly complex. The
wheel seat size of the axles is measured on an automated measuring unit and the dimensions
are transferred to two wheel borers. Paired wheels are custom bored as per the wheel seat
size to get correct interference fit. The wheels are then pressed on axle in a 300 T Wheel
press.

RWF manufactures cast steel wheels by a controlled pressure pouring process. In this
process, the raw material used is pedigree scrap (old used wheelsets, axles etc, rejected as
unfit for use by the Railways). The scrap steel is melted in Ultra High Frequency Electric Arc
furnace. The correct chemistry of molten metal steel is established through a Spectrometer.
The wheels are eventually get cast in the graphite moulds, which are pre-heated and sprayed.
After allowing for a pre-determined setting time the mould is spilt and the risers are
automatically separated from the cast wheel.

Figure 1 Wheels

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Chapter 2
Wheel Shop
The first unit of Rail Wheel Factory is wheel shop where Railway wheels are produced. The
wheels of a vehicle are the circular objects which are fixed underneath. It enables the vehicle
to move along the ground.

The railways wheels are circular objects made up of alloy steel and weigh about 500 kg.
There is variety of railway wheels. All types are produced in the same manner but they differ
in their dimensions. The wheel sits on the wheel seat of the axle.

In rail wheel factory, the wheel shop is divided into 3 portions where different operations
are performed on the wheel.

The Three parts are:

Melting Shop
Casting Shop
Cleaning Shop

MELTING SHOP
In the wheel shop of Rail Wheel Factory, the wheels are manufactured by casting process. For
this process molten metal is required. Hence the first process for the manufacturing of railway
wheels in the wheel shop is Melting of Metal scrap.
Melting is a process of converting the solid metal scrap into molten metal which can be used
for casting any shaped solid or hollow structure. When the temperature is raised very high
i.e., to a temperature above the melting point of that particular metal, under a very
sophisticated environmental condition, the solid metal changes its phase into liquid. This is
the basic principle of melting.

The furnace used in RWF for melting is ELECTRIC ARC type of furnace and the charge
used for producing molten metal are rejected wheels, axles etc.

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ELECTRIC ARC FURNACE:

An electric arc furnace utilizes the heat produced by the electric arc generated between two
conducting materials to melt the charge. It is used for melting cast iron and steels. High
thermal efficiency, rapid heating, close temperature control and strict atmosphere are few
characteristics of the furnace that lead to the production of good quality metal.

Direct arc electric type of furnace is used in RWF wheel shop whose construction
is as follow:

The Furnace consists of a heavy steel cylindrical shell with a spherical bottom lined
with refractory of the furnace that supports the charge and the walls are lined with
magnesite bricks.
The furnace is built on a tilting platform that facilitates tilting of furnace forward for
pouring molten metal into ladles. The furnace can also be tilted backwards for
inspection, charging metal, flux, deoxidiser etc. and for removal of slag through slag
door.
The roof of the furnace is made of steel lined inside with refractory bricks and can be
clamped in position. Metal can also be charged from furnace roof.
The roof is provided with 3 circular holes through which non-consumable graphite
electrodes are inserted. The electrodes can be raised and lowered by means of guides
and are usually water cooled to dissipate heat. They are connected to 3-phase power
supply.

Figure 2.1 Electric Arc Furnace

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Charge:
The charge used for the production of railway wheels in RWF is:

The rejected (damaged) axles from axle shop.

The rejected wheels from wheel shop.
Used axles and worn out wheels.
The chips formed during machining of axles.

The main material composition of the scarp is alloy steels, carbon, manganese
and silicon.

The composition for casting of wheels can be altered by re-carburising or de-carburising the

molten metal in the furnace in order to obtain the required wheel material composition.

Figure 2.2 Scarp Metal

Melting Process:
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Arc furnace works on the principle that, when an arc is struck between the electrodes and
charge material, heat is generated due to the resistance offered by the metal charge.

Level the furnace, remove the roof mast lock pin, raise the electrode and then
raise the roof of the furnace.
Charge approximately 900 to 1200kgs of claimed lime and 200 to250kgs of claimed
petroleum coke/graphite powder.
Charge scrap wheels or metal cakes/skull or risers with the help of magnet (2-
2.5MT approximately)
The electrodes are lowered down. On supplying the necessary current and voltage,
an arc is produced between the electrode and the charge material.
The gap between the electrode and charge is maintained by regulating the movement
of electrodes so that the arc remains between them and bums continuously melting
the charge material.
The flux melts and forms a slag that floats on the surface of the liquid metal. The
slag prevents oxidation, refines the metal and protects the furnace roof from
excessive heat.

REMOVAL OF SLAG:

After the liquid metal has been achieved the desired temperature, the electrodes are
raised to extinguish the arc and the furnace is tilted backwards to remove the slag.
After 45-55minutes of arcing, start emptying the scrap through slag door with
oxygen lancing pipe. Spread dolomite over the cleaned slag door. Clear slag door
scrap. Remove full slag before the temperature is 1630 degree Celsius. If the slag is
sluggish, shovel 25 -30kgs of fluorspar on the slag.
Temperature must be controlled so that the maximum slag is removed by 1650 degree
Celsius. Allow only thin layer of slag on the metal surface.
Care must be taken not to remove the metal through slag door throughout the
slagging operation. Keeps the slag door clean by removing the slag metal jam using
pipe or rod.
After reducing almost all first slag is removed add Ferro-manganese at around 1650
degree Celsius and 150kgs of reducing slag mixture into the furnace to make the
slag.

CASTING SHOP:

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In this part of the wheel shop the molten metal is poured into cope and drag assembly,
later the caste wheel is separated from cope and drag assembly and is made to undergo
certain heat treatment process.

The casting process begins with pouring of molten metal into cope-drag assembly, a
small period of air cooling and finally separating the cope-drag assembly to obtain
the caste wheel.

The ladle containing the molten metal placed in JMP is brought into the place of
pouring and graphite powder is sprayed into molten metal to prevent temperature
loss.
Cope and drag made up of graphite material is assembled and it is also
brought near the place of pouring.
This cope-drag assembly is placed on the covering of the ladle which contains a
centre circular hole. This hole houses the pipe through which molten metal gets
into the cope-drag assembly.
When external air pressure is applied on the covering of the ladle, the liquid metal
with high pressure comes out of the ladle through the centre pipe and gets into
the cavity present in cope-drag assembly.
Once this cavity is filled with molten metal, a graphite stopper present in the cope
and drag assembly will fall down to the bottom of the drag and prevents the further
flow of liquid metal from ladle into cavity. Also it prevents the liquid metal
flowing back to ladle from cavity.
The pouring of molten metal for each wheel takes about 80 sec and 30-31 wheels
can be cast in each heat.

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SPRUE WASHING:

After the controlled air cooling the wheel coming out of the kiln is at a temperature of
about 400-600 degree Celsius.

it contains a little part of the runner and riser which is not removed during splitting. The
part must be removed before the further cleaning of the wheel.

This is done in 2 ways:

1. Sprue grinding.
2. Induction process by electrode.
SPRUE GRINDING

In this method, the excess sprue material is removed by using grinding

wheel.
A grinding wheel mounted on the horizontal spindle is brought on the caste
wheel and hence the excess material is removed by the abrasive action of
the grinding wheel.
INDUCTION PROCESS
In this method a carbon electrode with copper coating is used to remove the excess
sprue material.
Once the electric current is sent through the electrode it produces a strong electric arc
between the carbon electrode and the wheel. The heat produced by this arc is more
than enough to melt and vaporize the excess metal.
The temperature of the wheel should not be less than 380 degree Celsius before
entering sprue washing.
The long rod placed in the centre during casting is cut just before sprue wash by
grinding plate.

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HUB CUTTING:

The centre portion of the wheel, where the axle fits in, need to be bored in order to remove
the caste portion from the wheel. This is done by up cutting process.

The hole is initially bored for a diameter lesser than required during this process
using Hub Cutting Machine. Hence the process is also called Hub cutting process.
The oxy-acetylene gas flame coming out of the nozzle at high pressure and
velocity is used for hub cutting.
The part of the pipe inserted during casting remains inside the caste wheel after being
cut at both the edges. This is called Pilot hole.
This hole is initially cleaned using pneumatic air, so that the hub cutting process can
be begun from this portion.
The oxy-acetylene gas flame is first directed to the pilot hole and then moved along the
radius and finally moved in a circular shape.
Hence the circular hub which is being cut falls after the arc completes a
circle of required radius.
The nozzle of the machine need to be regularly changed to prevent hub not falling
situation i.e., if insufficient flame is supplied for cutting due to defects in the nozzle,
the hub is not completely cut through the whole depth of the wheel. Hence, the cut
portion will not fall after complete circular path of the flame

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Chapter 3

Heat Treatment
To eliminate residual stresses that is present in the axle during forging and
subsequent cooling.
To homogenize the structure of the metal of forging.
To impart, to the axle that degree of hardness, this makes it most easy to machine.
To improve strength, toughness and other mechanical properties of the forged axle.
The rotary hearth furnace used for normalising has 7 zones.
First 4 zones are called as pre- heating zones, where the outer Layer of the wheel
and a few inner layers get heated.
The next 3 zones are called Soaking zone where in the heat spreads uniformly
including the core of the wheel.
The temperature of these zones varies for different types of Wheel.
Zone1 and 3 is 968 degree Celsius
Zone 3 to 7 is 938 degree Celsius
The fuel used in rotary hearth furnace is High Speed Diesel.
Each wheel remains in rotary hearth furnace for a duration of 1.5 hours before coming
out.
The temperature of the wheel coming out of the furnace is around 950 degree
Celsius.

Figure 3 Heat Treatment

Chapter 4
Cleaning
CLEANING:

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The Wheel coming out of the casting shop has a rough, uneven surface these
wheels need to be cleaned and finished before its usage. This cleaning, finishing and
certain tests are conducted in this cleaning shop.

The operations carried out on the wheel in cleaning shop are discussed below:

SAND BLASTING/STEEL BLASTING:

The surface of the wheel may contain dirt, ashes and even dust particles formed during
storing; also the wheels contain scales formed during heat treatment process.This unwanted
dust must be removed In order to obtain a clean surfaced wheel.

Steel blasting is the first process carried out in the cleaning shop.

In this process, tiny spherical metal particles with high velocity are made to strike the surface
of the wheel.Due to the impact of these particles the surface dust present on the wheel gets
removed due to the abrasive action.Hence the surface cleaned wheel is obtained after this
steel blasting process.After this steel blasting, the wheel is made to undergo two tests namely
Ultra Sonic test and Magnaglo test.Only those wheels passed in these test are sent to further
processing and the wheels with defects are sent back to machining accordingly. The rejected
wheels are sent to scrap yard and is recycled.

Figure 4

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Chapter 6
Advantages and Limitations
6.1 Advantages
6.2 Disadvantages

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Conclusion
FSW process has demonstrated its capabilities and been approved as a novel method for
joining aluminium and other metals. FSW is opening up totally new areas of welding
daily. The welding process improves existing structural properties and leaves the weld
cold. In some cases, if proper care is taken, weld properties equal those of the base
material.

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References
1. Murr, LE; Liu, G; McClure, JC (1997). "Dynamic recrystallisation in the friction-
stir welding of aluminium alloy 1100".
2. Reynolds, AP (2000). "Visualisation of material flow in autogenous friction stir
welds".
3. Krishnan, K. N. (2002). "On the Formation of Onion Rings in Friction Stir
Welds".
4. Bhadeshia HKDH; DebRoy T (2009). "Critical assessment: friction stir welding of
steels".
5. Mehta M, Arora A, De A, DebRoy T (2011). "Tool Geometry for Friction Stir
WeldingOptimum Shoulder Diameter".

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 EPOXY GRANITE AS A MACHINE TOOL BASE

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