Comparing bond formation mechanism between similar and dissimilar aluminium alloy friction welds

Ashfaq, Mohammed; Rao, KS Jagannatha

doi:10.1179/1743284713y.0000000360

Cited by 10 publications

(5 citation statements)

References 16 publications

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“…These microstructural examinations are consistent with the work of Li et al [35]. Referring to Figure 9, it can be seen that the width of DRZs decreases as the rotational speed increases consistent with the previous work which shows that narrow DRZs are associated with higher burn-off length due to higher rotational speed [36]. Another microstructural feature observed in Figure 9 is the presence of very fine grains in DRZs.…”

Section: Macro and Microstructuresupporting

confidence: 90%

Effect of Rotational Speed on Static and Fatigue Properties of Rotary Friction Welded Dissimilar AA7075/AA5083 Aluminium Alloy Joints

Sasmito

Ilman

Iswanto

et al. 2022

Metals

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In this work, rotary friction welding processes of dissimilar AA7075/AA5083 aluminium alloy rods with the diameter of 15 mm were performed at varying rotational speeds, typically 370 to 2500 rpm. The aim of this research is to improve mechanical properties, in particular, strength and fatigue performance of the weld joints. Several experiments including macro and microstructural examinations, Vickers microhardness measurements, tensile tests, fatigue tests and residual stress measurements were carried out. Results showed that at higher rotational speeds, typically 540 rpm or above, the dissimilar AA7075/AA5083 rotary friction weld joints revealed a static fracture in the AA5083 base metal side, indicating that the joint efficiency is more than 100%. It seemed that the best weld joint was achieved at the rotational speed of 1200 rpm, in which the friction heat was sufficient to form metallurgical bonding without causing excessive flash and burn-off. In such a condition, the fatigue strength of the weld joint was slightly higher than AA5083 base metal, but it was lower than AA7075 base metal. It was confirmed that the crack origin is observed at the interface followed by fatigue crack growth towards AA5083 side, and the growth of crack seemed to be controlled by microstructure and residual stress.

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Section: Macro and Microstructuresupporting

confidence: 90%

Effect of Rotational Speed on Static and Fatigue Properties of Rotary Friction Welded Dissimilar AA7075/AA5083 Aluminium Alloy Joints

Sasmito

Ilman

Iswanto

et al. 2022

Metals

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“…Further analysis was done using scanning electron microscope. In Al 2024-T6, fracture occurred in base metal, Al 6061-T6 and dissimilar welded sample shows cup and cone type fracture near the welded joint [16]. SEM images in Figure 5, show that the dissimilar welded joint has large number of porosities, then the same welded joints.…”

Section: Resultsmentioning

confidence: 93%

Mechanical Characterization of Rotary Friction Welded Dissimilar Aluminium Alloys

Asif Raza,

Hussain,

Malik

et al. 2023

MATEC Web Conf.

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Joining of the similar & dissimilar materials alloys using heat of the friction in currently being used, especially for non-ferrous alloys which are considered as non-weldable alloys. Al 2024-T6 & Al 6061-T6 having length of 70mm and 12mm diameter were welded by using the friction welding process. Similar and dissimilar welded samples were obtained by applying different combinations of welding parameters like friction pressure 30bar, forging pressure from 50 to 60 bar, and rotational speed of 2200 rpm. Vickers microhardness and Tensile test was performed on similar and dissimilar welded samples. Test shows that ultimate tensile strength and hardness of the similar welded joint was greater than their respective base metals welds. Dissimilar weld samples have hardness and ultimate tensile strength greater than the base Al 6061-T6, and less than the base Al 2024-T6. From results, it was clearly shown that as forging pressure increased from 50 to 60 bar, ultimate tensile strength and hardness of the similar and dissimilar welded samples increased. Joints were analysed to investigate the fractography of all welded samples. All welded samples fractured on the base metal alloy and show the formation of the cup and cone like structure which indicate the ductile fracture of the joints.

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“…Ashfaq and Rao [ 11 ] compared the bond formation mechanism of rotary friction welded similar (AA2024 and AA6061) and dissimilar (AA2024/AA6061) aluminum alloys. They reported that the burn-off length had no significance on the rotary friction welded similar aluminum alloys.…”

Section: Introductionmentioning

confidence: 99%

Effect of Heat Treatment on the Microstructure and Mechanical Properties of Rotary Friction Welded AA7075 and AA5083 Dissimilar Joint

et al. 2023

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The present work aims to investigate the changes in the microstructural and mechanical properties of various pre- and post weld heat treatments (PWHTs) on rotary friction welded dissimilar (AA7075 and AA5083) aluminum alloys. The investigation focused on the evolution of weld macro- and microstructures, as well as the changes in hardness and tensile properties resulting from friction welding. The joint integrity was studied through various characterization techniques, and no cracks or incomplete bonding was observed. The study found that the dissimilar joints of the AA7075 and AA5083 alloys displayed higher flash formation on the AA7075 side, which has a lower melting temperature compared to the AA5083 alloy. Various zones were identified in the weld region, including the dynamic recrystallized zone (DRZ), the thermomechanically affected zone (TMAZ) consisting of TMAZ-1 (elongated grains) and TMAZ-2 (compressed/distorted grains), the heat-affected zone (HAZ), and the base metal (BM) zone. The rotary friction welded sample AA5083/AA7075-PWHT joint exhibited the highest strength (yield strength (YS): 195 ± 3 MPa, ultimate tensile strength (UTS): 387 ± 2 MPa) among all the other welded conditions, and this may be attributed to the major strengthening precipitates MgZn2 (of AA7075) formed during postweld aging. All dissimilar welds failed in the HAZ region of the AA5083 side due to the formation of coarse grains, indicating the weakest region.

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Comparing bond formation mechanism between similar and dissimilar aluminium alloy friction welds

Cited by 10 publications

References 16 publications

Effect of Rotational Speed on Static and Fatigue Properties of Rotary Friction Welded Dissimilar AA7075/AA5083 Aluminium Alloy Joints

Effect of Rotational Speed on Static and Fatigue Properties of Rotary Friction Welded Dissimilar AA7075/AA5083 Aluminium Alloy Joints

Mechanical Characterization of Rotary Friction Welded Dissimilar Aluminium Alloys

Effect of Heat Treatment on the Microstructure and Mechanical Properties of Rotary Friction Welded AA7075 and AA5083 Dissimilar Joint

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