Abstract
Friction welding is becoming a viable replacement of conventional joining methods. Continuous Drive Friction Welding (CDFW) is a type of friction welding used to join rods, tubes and similar shapes. Usually, the process contains a friction stage and a forging stage and the process parameters would be ticked accordingly. AA6061 is an Mg and Si aluminum alloy that is widely used in many industries. This research investigates the effect of friction time on the mechanical properties of AA6061 joints made with CDFW and the relation to the microstructure of the material and thermal profiles. It was found that AA6061 does not require a forging stage where solid joints are obtained without forging and did not fracture within the welding zones. Also, it was concluded that the process parameters are to be tailored in a way that produces a specific type of grain structure within the welding areas.
Highlights
Friction Welding (FW) is a form of joining materials in solid phase
The samples welded at 5s had a less plastic deformation curve since each curve represents an average of three curves
One of the samples welded at 5s had poor tensile properties, on average, samples welded at 5s had less plastic deformation
Summary
Friction Welding (FW) is a form of joining materials in solid phase. Continuous Drive Friction Welding (CDFW) is a form of RFW that is used to join rods and tubes of similar and dissimilar materials. Such welding techniques allow the materials to be joined without reaching the melting temperature and prevent the formation of intermetallic layers in similar material welding. Five process parameters are affecting CDFW: rotational speed (RS), friction pressure (Pf), friction time (tf), upset pressure (Pu), and upset time (tu). Most studies consider a range of rotational speed, a variety of friction pressure, a range of upset pressure, and some specified times of friction or burn-off lengths. Most of the relevant literature is focused on the CDFW of Aluminum
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