Investigations on the effect of friction crush welding parameters in joining 6061 aluminium alloy to 304 stainless steel

Singh, Prabhakar; Deepak, Dharmpal; Brar, Gurinder Singh

doi:10.1007/s12206-023-0336-6

Cited by 3 publications

(2 citation statements)

References 20 publications

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“…Kumar and Brar (2021) developed a numerical model to forecast the temperature pattern and mechanical behaviour of identical joints made of Aluminium and Copper in an FCW of sheet metal sections [25]. Singh et al (2023) examined the FCW between dissimilar junctions made of Aluminium 6061-T6 and Stainless Steel 304 using feed speed of 15, 30, and 45 mm/min and tool revolutions of 2000, 3000, and 4000 rpm. Through microstructure welding was shown to be more stable than other operating conditions when done at a feed speed of 30 mm/min and tool speed of 3000 rpm [26].…”

Section: Fig 1 Friction Crush Welding Schematic Drawingmentioning

confidence: 99%

“…Singh et al (2023) examined the FCW between dissimilar junctions made of Aluminium 6061-T6 and Stainless Steel 304 using feed speed of 15, 30, and 45 mm/min and tool revolutions of 2000, 3000, and 4000 rpm. Through microstructure welding was shown to be more stable than other operating conditions when done at a feed speed of 30 mm/min and tool speed of 3000 rpm [26]. Various studies have observed the welding of various types of Aluminium and Steel alloys using the FSW process [1,4,5,13].…”

Section: Fig 1 Friction Crush Welding Schematic Drawingmentioning

confidence: 99%

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Friction Crush Welding of Dissimilar Materials: Numerical Modelling and Experimental Investigation

Kumar,

Brar,

Singh

2023

Preprint

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Several present day applications require joining of dissimilar materials by solid state processes. In this research work, two dissimilar metals – Aluminium and Steel were joined with a newly developed Friction Crush Welding (FCW) process. Macro-structure images along with X-Ray Diffraction (XRD) pattern were used to investigate the prepared samples. This work also aims to develop a novel Finite Element (FE) model based on ABAQUS for FCW of Aluminium-Steel materials. The numerical model was developed as a three-dimensional, explicit non-linear model utilising the Lagrange technique in ABAQUS. The developed FE model was validated by comparing the simulation results with experimental temperature data obtained by infrared thermography. The predicted temperature values from FE model are in excellent agreement with the experimentally measured values. The influence of welding variables, i.e., tool rotational speed (2000, 3000 and 4000 rpm) and welding speed (15, 30 and 45 mm/min) on temperature was also investigated. Results show that best weld structure is obtained when welding is performed at speed of 30 mm/min and tool rotational speed of 3000 rpm. The developed FE model of the FCW process may be used for predicting the temperatures and predicting the weld structure.

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Section: Fig 1 Friction Crush Welding Schematic Drawingmentioning

confidence: 99%

Section: Fig 1 Friction Crush Welding Schematic Drawingmentioning

confidence: 99%

Friction Crush Welding of Dissimilar Materials: Numerical Modelling and Experimental Investigation

Kumar,

Brar,

Singh

2023

Preprint

Self Cite

View full text Add to dashboard Cite

show abstract

Multi-Response Optimization of Wear Behaviour in FSWed AA6063-T6 Alloy Using Taguchi Grey Relational Analysis

Khatak,

Kaushik,

Kumar

et al. 2024

J. Inst. Eng. India Ser. D

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Development and validation of finite element model of dissimilar friction crush welding for automotive applications

Kumar,

Brar,

Singh

2024

Proceedings of the Institution of Mechanical Engineers, Part L:

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Several present-day applications require the joining of dissimilar materials by solid-state processes. Aluminum-stainless steel sheet metal joining finds its application in the Automotive industry. In present work, two dissimilar sheet metal workpieces of Aluminium and Stainless Steel were joined with a newly developed Friction Crush Welding (FCW) process. Macro-structure images along with an X-ray diffraction (XRD) pattern were used to investigate the prepared samples, and a hook-like structure was found along with a U-shaped interface and intermetallic phases such as FeAl2, Fe2Al5, FeAl3, Al, and ϒ-Fe. The work aims to develop a novel Finite Element (FE) model based on ABAQUS for FCW of Aluminium-Stainless Steel. The FE model was developed as a three-dimensional, explicit nonlinear model utilizing the Lagrange technique. The developed FE model was validated by comparing the FE model results with experimental temperature data obtained by infrared thermography. The predicted temperature values from the FE model are in excellent agreement with the experimentally measured values. The influence of welding variables, i.e., tool rotational speed (2000, 3000, and 4000 rpm) and welding speed (15, 30, and 45 mm/min), on temperature, was also investigated. It was found that increasing tool rotational speed increases temperature but decreases stress distribution, whereas the correlation between feed rate and temperature was inversely proportional. Results show that the best weld structure was obtained when welding was performed at a welding speed of 30 mm/min and tool rotational speed of 3000 rpm. The developed FE model may be used to predict the temperature and weld structure.

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Investigations on the effect of friction crush welding parameters in joining 6061 aluminium alloy to 304 stainless steel

Cited by 3 publications

References 20 publications

Friction Crush Welding of Dissimilar Materials: Numerical Modelling and Experimental Investigation

Friction Crush Welding of Dissimilar Materials: Numerical Modelling and Experimental Investigation

Multi-Response Optimization of Wear Behaviour in FSWed AA6063-T6 Alloy Using Taguchi Grey Relational Analysis

Development and validation of finite element model of dissimilar friction crush welding for automotive applications

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