Abstract
Friction welding was applied to dissimilar aluminum cast bars alloyed with 2 and 8% copper and the effects of upset time on joint properties were evaluated in this study. The welding process was carried out by a vertical milling machine. Tensile test results show that the ultimate tensile strength increased with an increase in upset time and it reached 88% for Al-2%Cu and 74% for Al-8%Cu base metals. The heat affected zone, thermo-mechanical affected zone, and weld metal were detected in this joint by optical examination, in addition to the base metals. A peak temperature of 436 °C was measured in the weld zone. Hardness values also varied according to microstructural changes. The highest hardness values were detected in the weld metal and its average hardness was 217 Brinell.
Highlights
Aluminum-copper (Al-Cu) cast alloys (2XX.X series) are widely used in various industrial applications due to their high strength and hardness properties in the ascast state in spite of their low corrosion resistance, low fluidity and ductility
They observed that the tensile strengths of the joints increased up to a certain value with an increase in friction pressure and that the hardness generally increased with increasing friction and upset pressures, but that hardness values decreased with increasing upset time
Manideep and Balachandar [14] examined the microstructure and hardness distribution of Friction welding (FW) parameters for joining of dissimilar stainless steels. They explained that high upset pressure resulted in a fine grain structure in heat affected zones (HAZ) and high hardness, while higher friction pressure leads to grain coarsening for FW of AISI 321 to AISI 430 stainless steel
Summary
Aluminum-copper (Al-Cu) cast alloys (2XX.X series) are widely used in various industrial applications due to their high strength and hardness properties in the ascast state in spite of their low corrosion resistance, low fluidity and ductility. Some process parameters have significant effects on producing sound welds These are: (i) rotational speed, (ii) friction pressure, (iii) friction time, (iv) forging (upset) pressure, and (v) forging time. Sathiya et al [11] looked at the effects of FW parameters in joining ferritic stainless steel pieces They found out that friction time should be kept as short as possible, while friction and forging pressures should be as high as possible in order to obtain high joint strength. A similar study about dissimilar 6063 Al alloy/ austenitic stainless steel was carried out by Sammaiah et al [13] They recommended low friction pressure and high upset pressure in order to obtain high joint strength. They found that the tensile strength of the joints increases up to a certain peak value and slightly decreases with higher friction time
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