Abstract
Friction crush welding applications (FCW) provides versatile applications in sheet metals welding. In this work, different tool rotational speeds (220, 410, 920, 1500 rpm) and feed rates (20, 43, 80,150 mm/min) were used to weld oxygen-free copper sheets with flanged edges. Evaluation of Cu-Cu joints was performed successfully using optical microscope, vickers hardness and tensile test. The results showed that the microstructure was significantly influenced by welding parameters used. Different defects were recognized in the welding zone. The highest hardness of 63 HV and tensile strength of 105 MPa were obtained at tool rotational speed of 1500 rpm and feed rate of 115 mm/min.
Highlights
Friction welding is used for joining metals and alloys in a solid state where the resulting heat is responsible for welding due to a relative movement between two components under pressure
2017 [9], demonstrated that friction crush welding of 2 mm thick 6061T-6 Al alloy using tool rotational speeds of 220- 740 rpm and feed rates of 15-45 mm/min was achieved by a specific tool profile design
thermodynamically-affected zone (TMAZ) was characterized by thermo-mechanical deformation which results in a recrystallized fine - grained microstructure
Summary
Friction welding is used for joining metals and alloys in a solid state where the resulting heat is responsible for welding due to a relative movement between two components under pressure. Friction stir and crush welding processes are other group of friction welding categorized according to the relative motion between a non-consumable tool and the workpiece, Ranjan S. et al, 2007[1], Sandeep K. et al, 2012[2], Huda M. et al, 2013[3], Pulak M. In friction crush welding (FCW), the coalescence among metals or alloys is achieved mainly through two processes represented by friction-based heating, and crushing mechanism where the feed rate and. The impetus for this work is to study the possibility of achieving friction crush welding of flange edged copper sheets using tool rotational speeds of (220 - 1500 rpm) and feed rates of (20 - 150 mm/min). The microstructure and mechanical properties of the friction crush welded Cu-Cu joint are studied in this work. The characterization of the defects formed in the weld joints during welding is achieved
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