Abstract
In the previous study, Continuous Drive Friction Welding (CDFW) had been investigated to determine the strength of joining, burn off, and temperature distribution. In this study, Dissimilar Metal CDFW was studied to assess temperature cycle analysis. Aluminum 6061 (A6061) workpiece was fixed, and an AISI 304 was rotated at 1,000 rpm. The temperature distribution was measured by using an OMEGA Thermocouple Data Logger. The thermocouple was installed near joining location 5 mm distance from the joint. In the computer simulation, the geometry of CDFW was designed using ANSYS Design Modeler. Computer simulation with transient thermal combined with static structural analysis was modeled by using ANSYS academic version Rel. 18.1. The boundary condition was set based on the experimental condition, where the Aluminum 6061 was fixed, and the AISI 304 was rotated at 1,000 rpm. Based on the experimental results, the temperature profile as the outer surface of the distance of the center of the joint location can be measured. From the simulation results, it can be seen that the temperature cycle profile is the same trend with experimental results. The mechanical properties provided that this phenomenon is shown in the characteristics of tensile strength, microstructure and hardness test as model analysis to denote the connection from temperature cycle profile with mechanical properties test results. Microstructure observation revealed that there is no significant difference in grain size and grain shape on the stainless steel side. Computer simulation results showed that the welded aluminum-stainless steel joint shows marks of heat affected zone near the weld interface only on the aluminum side, and this was confirmed by experimental results
Highlights
Dissimilar metal welding had been a trend of research due to many problems and became challenges to be resolved to provide industrial applications
Studies are aimed at determining the thermal cycle profile and the shape of the flash in Continuous Drive Friction Welding (CDFW) welding by computer simulation and experimental methods to improve the strength of CDFW joints
It can be denoted that there is no significant difference in grain size and grain shape on the stainless steel side
Summary
Dissimilar metal welding had been a trend of research due to many problems and became challenges to be resolved to provide industrial applications. The problems of dissimilar metal welding are different thermal and mechanical properties. This process produces under high friction pressure, and interface temperature, the elements in different materials will show unusual behavior, and dissimilar deformation. On another side, dissimilar metal welding is conducted with high thermal conductivity, large differences in forging temperatures, and the formation of brittle intermetallic compounds. Mechanism of friction welding heat is formed by direct conversion of mechanical energy into thermal energy at the interface of the workpieces. A weld under the compressive contact force of one rotating and one stationary workpiece is produced as a solid-state joining process. Studies are aimed at determining the thermal cycle profile and the shape of the flash in CDFW welding by computer simulation and experimental methods to improve the strength of CDFW joints
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