Comparison of tool wear during friction stir welding of Al alloy and Al-SiC metal matrix composite

Abstract

Aluminum matrix composites have received considerable attention due to their high specific strength and specific stiffness, high hardness, and wear resistance along with being light in weight. These composites are preferably joined using friction stir welding process. The major concern in friction stir welding is the wear of the welding tool pin which is the backbone of the process. The wear is due to the prolonged contact between the tool and the harder reinforcements in the composite materials. The present work deals with the study of tool wear and its surface roughness with respect to different selected friction stir welding parameters such as rotational speed, transverse speed, length of weld, and different composition of Aluminum composite. It was found that the total amount of material removed from the tool and the surface roughness of the tool is in direct proportion to the rotational speed of the tool and the length of the weld but inversely proportional to the transverse rate. The increase in wt.% of SiC reinforcement leads to the higher tool wear but reduces the surface roughness of the tool.

Impact of ultrasonic vibration power and tool pin profile on mechanical and microstructural behaviour of friction stir welded dissimilar aluminium alloy joints

“…The weld joint’s microhardness has been evaluated in five distinct zones to pinpoint the weak areas such as WSZ, retreating side heat affected zone, retreating side thermo-mechanical affected zone, advancing side heat affected zone and advancing side thermo-mechanical affected zone. The grain structure and dislocation density cause variations in microhardness distributions across the joints (Bist et al , 2021). The strength of a dissimilar aluminium alloy joint is regulated by its microhardness.…”

Investigation of the microstructure, mechanical and wear performance of friction stir-processed AA6061-T6 plate reinforced with B4C particles surface composite

“…Equation (1) was used to determine each reinforcement particle’s volume. 35,36 For conducting a mechanical, wear, and microstructural examination, FSP specimens were cut from the center of pass in a direction perpendicular to the processing procedure. Wire electrical discharge machine was used to cut all specimens from FSP AA6061-T6 with and without B4C particles.…”

Effect of friction stir processing parameters on producing AA6061/ tungsten carbide nanocomposite

“…A tool made of hardened H-13 steel as represented in Figure 2(c) with a threaded pin profile M6 mm and 5 mm height and a shoulder diameter of 18 mm was used to introduce the reinforcement particles in the matrix. 43,44…”

“…A tool made of hardened H-13 steel as represented in Figure 2(c) with a threaded pin profile M6 mm and 5 mm height and a shoulder diameter of 18 mm was used to introduce the reinforcement particles in the matrix. 43,44 Methods Experimental design using Taguchi methods. It is shown that FSP process parameters, such as rotational speed, transverse feed, number of passes, tool penetration depth, pin profiles and reinforcement volume fraction significantly influence the FSP process and play a vital role in the characteristic and mechanical properties of the fabricated composite.…”