Friction welding of dissimilar aluminium 6061and SS 430F steel and its characterizations

Abstract

Friction welding is a process to weld similar and dissimilar metals and it finds widespread applications in mass production method for joining the parts in various industries. In the present work, the joining of two dissimilar materials such as Aluminium 6061 and SS 430F steel using friction welding was investigated. Aluminium 6061 and SS 430F steel bars were cut into pieces having the dimension of 75 mm x 20 mm as length and diameter. Process variables such as upset force, friction force and burn off length were considered for this friction welding process. The welded region was analysed to investigate the mechanical testing like hardness test, impact test, bend test and pull load test. The XRD studies indicated the presence of Al, Fe and intermetallic phases in the welded region. The hardness studies were conducted at different zones of the samples indicating highest hardness at the weld interface. Toughness and bending strength increased and pulling strength decreased with an increase in friction force and burn off length for low upset force as well as high upset force. The SEM image of fracture surface of pull load test specimen showed the ductile failure of friction welded joint. This solid-state structure of dissimilar materials can be used in the structural applications of aircraft, marine and automobile engineering with an aim to meet weight reduction.