Experimental analysis of rotary friction joining process by EN1A bright mild steel under normal air and wet environment condition

Abstract

Rotary friction welding is a solid state metal joining process and it has many applications in future upcoming days because of its advantages like without fumes and smokeless operation. In this process heat generates through mechanical friction between one continuously rotating component and one stationary component. After heat generation phase an additional forging force is applied which completes coalescence. Since no melting of material occurs during friction welding, but metal gets deform after heat generation at welding zone. The main advantages of friction welding include low distortion, absence of weld related defects, high joint strength, ease of automation, ability to weld alloys and metals which are not weldable by conventional welding methods. In this research work weld specimens were prepared on all geared lathe conventional machine by consideration of parameters like rpm of rotating specimen, friction and forging force applied. This study includes that joining of metal initially carried out under normal atmospheric conditions i.e. air environment and secondly, continuous stream of water under the wet environment. The materials were used EN1A bright mild steel and only similar combinations were used for study purpose. An experimental setup was prepared for force measurement on all geared lathe machine. Mechanical properties of joints were evaluated utilizing tensile test and hardness at heat affected zone.