Rotary Friction Welding Research Articles

Study of the effect of nano ZrO2 and TiO2 and rotation speed on friction behavior of rotary friction welding of HIPS and PP

The purpose of this project was to introduce a way to improve the mechanical properties of dissimilar welded material, which provides benefits such as affordability, high speed, and a suitable bond property. This experimental project applies the friction welding method, including combining parameters, such as a numerical control machine, two different speeds, and three different cross sections, including flat, cone, and step surfaces. When the welding process was done, samples were implemented and prepared via a bending test of materials. The results have shown that, besides increasing the machining velocity, the surface friction increased, and so did the temperature. Considering the stated experimental facts, the melting temperature of composite materials increased. This provides the possibility of having a better blend of nanomaterial compared to the base melted plastics. Thus, the result showed that, besides increasing the weight percentage of nanomaterial contents and machining velocity, the mechanical properties increased on the welded area for all three types of samples. This enhancement is due to the better melting process on the welded area with the attendance of various nanoparticle contents. Also, the results showed that the shape of the welding area could play a significant role, and the results also change drastically where the shape changes. Optimum shape in the welding process has been dedicated to the step surface. The temperature causes the melting process, which is a significant factor in the friction welding process.

Effect of Rotational Speed on Static and Fatigue Properties of Rotary Friction Welded Dissimilar AA7075/AA5083 Aluminium Alloy Joints

In this work, rotary friction welding processes of dissimilar AA7075/AA5083 aluminium alloy rods with the diameter of 15 mm were performed at varying rotational speeds, typically 370 to 2500 rpm. The aim of this research is to improve mechanical properties, in particular, strength and fatigue performance of the weld joints. Several experiments including macro and microstructural examinations, Vickers microhardness measurements, tensile tests, fatigue tests and residual stress measurements were carried out. Results showed that at higher rotational speeds, typically 540 rpm or above, the dissimilar AA7075/AA5083 rotary friction weld joints revealed a static fracture in the AA5083 base metal side, indicating that the joint efficiency is more than 100%. It seemed that the best weld joint was achieved at the rotational speed of 1200 rpm, in which the friction heat was sufficient to form metallurgical bonding without causing excessive flash and burn-off. In such a condition, the fatigue strength of the weld joint was slightly higher than AA5083 base metal, but it was lower than AA7075 base metal. It was confirmed that the crack origin is observed at the interface followed by fatigue crack growth towards AA5083 side, and the growth of crack seemed to be controlled by microstructure and residual stress.

回転摩擦接合による自動車エンジン部品の製法

Crankshafts for automobile engines are usually manufactured by hot forging and machining. Since the projected area of this part is quite large, a large forging press and hence a large capital investment are required. It is expected that capital investment will be reduced by dividing and forging a crankshaft in parts that are then joined it later. This research is a study on the manufacturing method of joining this sectionally forged product by rotary friction welding (RFW) to make a crankshaft. First, we conducted a basic experiment on the joining conditions of the material by RFW and later conducted an experiment to join the parts of the crankshaft. We were able to propose a manufacturing method that results in the same strength as a normal hot forged crankshaft as well as achieve the desired angular alignment between the joined parts.

Strain hardening behavior of friction welded beta titanium alloy Titan 1023 used for aeronautical applications

The experimental true stress – true strain data has been evaluated for the solution treated and aged beta titanium alloy Titan 1023 in comparison with the solid state welded samples. 14 mm diameter rods extracted out of Titan 1023 rolled bars were welded employing rotary friction welding with optimized parameters. Strain hardening parameters for samples in solution treated, aged condition and welded samples were determined using Holloman equation with the data obtained by carrying out tensile testing at ambient temperatures employing a strain rate of 3x10−4S−1. Strain hardening rate in terms of Crussard-Jaoul (C-J) plots of the alloy in all pre and post treated conditions were elucidated. Work hardening capacity of the alloy in STA and welded conditions were determined and presented. The effect of resultant microstructures on the strain hardening behavior is discussed in the current study.

Study of grain refinement on piston combustion bowl using friction welding

IC engines are subjected to constant heat and friction when the engine is running at full capacity and maximum load. In the piston head, the part known as the combustion bowl often is exposed to massive pressure and high heat temperatures, which can lead to crack openings in it eventually leading to engine breakdown.Hence, this experiment was conducted to study the grain structures of the materials used in the combustion bowl, to study its refinement and also find the hardness of the material. H13 3000 series Aluminum and SS304 steel were the materials chosen to do the experiments. Six welding samples was processed in which two are of Aluminum-Aluminum, two are Steel-Steel and two are Steel-Aluminum. A rotary friction welding machine was used for the experiment. The objectives of the experiment were to study the porous structure of the welded region, to find the grain refinement in all of the six experiments performed in all of the cases, and to study the microstructure by performing the Vickers hardness test to inspect the hardness of the welded region in all six cases.Upon inspection it was found that there is a significant increase in percentage of hardness in the welded zones of steel samples when compared to aluminium samples.

Rotary Friction Welding and Dissimilar Metal Joining of Aluminium and Stainless Steel Alloys

Friction welding (FW) is cost-effective, efficient, occupational safer and also eco-friendly in the absence of pollution, smoke, fume, and IR radiation during welding than conventional welding technologies. In this paper, the joining of aluminium AA6063 and steel SS304 dissimilar metal is explained with different faying surfaces and their SEM images of weld interface (WI), joint quality, tensile and yield strength, and the axial shortening are evaluated and compared. The joint quality factor of the experiment faying surface modification ‘E3’ was the maximum and about >100% with 236 MPa strength. The axial shortening was also less than 27 mm. The joint with hemispherical faying surface showed ‘U’ shaped WI and the joint with taper faying surface showed ‘V’ shape WI. So, the cross-sectional area of WI can be increased and the strength also increased. FW yields very high strength, low-stress weld with no weld defects such as porosity, voids etc. Here, in most cases, the joint strength is equal to base metal strength and it can avoid fastening to join two metals. FW has a minimal and narrow heat-affected zone (HAZ) of few microns size that differentiates FW from other welding techniques. The grain size of HAZ is directly proportional to the heat input during welding. During fusion welding of dissimilar materials, a lot of intermetallic compounds are formed at the weld interface and that will lead to poor strength of the welding because they have different chemical and mechanical qualities; therefore FW is a good choice for joining dissimilar metal rods as the intermetallic compounds can be reduced by FW.

Tribological properties of the rotary friction welding of wood

Wood–wood friction is an ancient subject, and its related mechanisms have been elucidated. However, the tribological mechanism of wood–wood friction at a high speed is still unclear. In this paper, an experimental equipment of wood friction welding was designed and fabricated. The influences of welding equipment and wood parameters on frictional force, normal force, and welding interface temperature were studied. Results show that the speed of welding into wood has a significant effect on interfacial force and normal force. Increase in wood moisture content reduces frictional and normal forces, and increase in fiber angle increases frictional force, normal force, and welding interface temperature. This study provides theoretical and technical basis for the study of wood friction welding.

Cellular automata modeling for rotary friction welding of Inconel 718

ABSTRACT This work investigates the microstructure evolution during the rotary friction welding (RFW) of Inconel 718 alloy. A cellular automata (CA) approach is implemented to evaluate a cylindrical component (at weld center and edge wall), predicting dynamic recrystallization (DRX) and grain size of friction welds. The input variables for RFW were rotational speed (500, 1000, and 1200 rpm), feed rate (2 mm/s), and feed distance (3.6 mm). The CA model is based on the Laasraoui-Jonas model and explains intricate grain transformation in terms of microstructure, temperature, strain, and strain rate. Calculated grain consists of very fine grain structure at the stir zone followed by the thermo-mechanical affected zone, where partial recrystallized microstructure was present. The average grain size was 2.5 µm, which is comparable to reported experimental values. The grain analysis revealed that temperature and strain are most affecting factors to attain a refined microstructure. The strain rates predicted for both center and edge locations of the weld were found to be higher as rotational speed increased. A steady strain distribution is noted at greater temperature for all the rotational speeds. The results of this work contribute toward the understanding of microstructure and mechanical response for RFW of Inconel 718.

Characterization of ultrafine-grained copper joints acquired by rotary friction welding

Copper rods with ultrafine-grained microstructure, obtained by multi-turn ECAP processing, were subjected to Direct Drive Rotary Friction Welding using various processing parameters, such as rotational speed and pressure, which resulted in different energy and heat input. Even though friction welding is a high energy process, by a proper selection of processing parameters it was possible to maintain grain size at around 0.7 µm in the weld zone and preserve the UFG microstructure. These microstructural features translated into mechanical properties: the YS for those specimens was around 330 MPa. Processing parameters that resulted in a larger heat input caused an increase in grain size to around 2 µm; this, however, increased ductility and led to a uniform elongation exceeding 5%. Corrosion resistance in the stir zone increased, as was evident in the higher open circuit potential and higher corrosion potential in comparison with base material; the observed differences were about 50 mV. These changes can be explained by the higher fraction of HAGBs in the SZ.

A solid-state joining approach to manufacture of transition joints for high integrity applications

Manufacture of a transition hybrid coupling from two different steels, medium carbon S355J2 and stainless 316L, has been demonstrated using two different solid-state joining routes, forge welding (FW) and rotary friction welding (RFW). An additional manufacturing route, electron beam welding (EBW), was also employed in investigating its feasibility for such application. Mechanical and microstructure properties of the final components manufactured from the three different routes have been compared. Finite element (FE) analysis was utilised to determine optimal geometries for the FW and the RFW preform rings and identify optimal parameters for both processes. Of the three manufacture routes, the FW produced an instant diffusion-like bond with a single forging stroke on a 2100T screw press with the thinnest weld interface and most uniform hardness distribution at either side of the joint. The RFW part, manufactured on a 125T RFW machine, also exhibited a very thin weld interface, yet slightly thicker compared to the FW case, with small variations in the hardness distribution at either side. The EBW produced markedly thicker weld interface compared to the two solid-state routes. The EBW part exhibited significant variation in hardness distribution across the weld exhibiting peak hardness in the weld indicating requirements for a post-weld heat treatment (PWHT). Both the FW and the RFW process routes exhibited very uniform micro-hardness and microstructures across the weld interface in contrast with the EBW process in as-manufactured condition.

Microstructure and Mechanical Property Correlation Between Rotary Friction Welded Nitinol–Nitinol Joints

In the present study, a rotary friction process was used to join nitinol in a similar welding combination. Macro- and microstructure characteristics of the weld zone were compared with adjacent zones and the base metal. The hardness and tensile properties of the joints were evaluated, and the results were discussed in relation to the weld microstructure. The weld macrostructure revealed a uniform flash around the circumference of the weld. The optical microstructure of the welded sample revealed fine recrystallized grains at the weld interface due to heavy deformation followed by dynamic recrystallization. The phase transformation behavior of the base metal and welded samples was studied by using a differential scanning calorimeter (DSC). The drift in phase transformation temperatures after rotary friction welding may be attributed to fine grain formation at the weld interface. Friction welded samples exhibited improved yield strength and hardness values compared to the base metal due to grain refinement at the weld interface.

An investigation on the effect of nanoparticle reinforcement and weld surface shape on bending behavior of rotary friction-welded high-density polyethylene

In this research, high-density polyethylene rods were joined together using rotary friction-welding. The effects of nanoparticle reinforcement and weld surface shape on the welded joint strength were investigated. To this aim, high-density polyethylene rods with a length of 50 mm and a diameter of 22 mm were machined, and three weld surface shapes, that is, flat, step, and conic shapes (on male and female counterparts), were created. The high-density polyethylene rods were rotary friction-welded with the addition of ZnO and SiO2 nanoparticles. The bending strength of rotary friction-welded rods was assessed by conduction of three-point bending tests. The results showed that both the weld surface shape and nanoparticles influence the bending strength of the welded joints. It was found that the step sample welds have higher bending strength (average bending depth and force of 6.27 mm and 2027.8 N, respectively). Furthermore, except for the case of flat samples, the addition of the reinforcement nanoparticles resulted in the improvement of the bending strength of the rotary friction-welded rods.

Influence of process parameters on hot tensile behavior of rotary friction welded In 718/AISI 410 dissimilar joints

• Effect of rotary friction welding parameters was discussed by mechanical and metallurgical aspects. • Rotational speed is found as an influencing process parameter among other RFW parameters. • Evaluated room and elevated temperature properties on dissimilar joints. • Weld failure characteristics were analyzed and detailed in the dissimilar joints. The dissimilar joints are adopted to enhance the functionality of components and improve the working limits in critical applications like nuclear power plants and gas turbines. This investigation studied the influence of process parameters on dissimilar joining of Inconel 718 and AISI 410 martensitic stainless steel by Rotary Friction Welding (RFW) process. The major welding parameters of RFW were Rotational Speed, Friction pressure, Forging pressure, Friction time, and Forging time. Among these welding parameters, the joint strength was influence by the rotational speed. The evaluated tensile and microhardness properties were correlated with microstructures. The hot tensile properties result that the strength decreased with an increasing the operating temperature. The weld failure occurred in both a weld interface and thermomechanical affected zone, which is due to the formation of martensite and intermetallic.

Exploration of Rotary Friction Welding Technique

Abstract Friction welding is a solid-state welding system which welds materials without authentic melting it. This study explores papers of different researchers on the friction welding method and it has been observed that the welding parameters like friction time; friction pressure, forge time and forge pressure highly affect properties of welded joints. The reason for this investigation is to exhort industry and the insightful world regarding advantages of revolving friction welding so the technique may be utilized in an ideal manner.

Microstructural response at the interface and its effect on the fatigue fracture behavior of rotary friction welded dissimilar titanium alloys: Ti–5Al–2Sn–2Zr–4Mo–4Cr (Ti17) and Ti–6Al–2Sn–4Zr–2Mo (Ti6242)

Ti17 and Ti6242 tubes were subjected to rotary friction welding to fully understand the microstructural response and its effect on the fatigue fracture behavior of the dissimilar joint. Experiment was conducted using friction linear speed 1 m s−1, friction pressure 80 MPa, burn-off length 5 mm and forging pressure 120 MPa as welding parameters. Electron backscattered diffraction was utilized to systematically examine the microstructures and microtextures across the Ti17/Ti6242 friction welded interface. Thereafter, two fatigue tests were conducted to characterize the fatigue performance of Ti17/Ti6242 joint, one of which is used to identify the fatigue fracture location of the joint and another one to analyze the fatigue fracture behavior. Results clinched that the formation of joint exhibited 600 μm thick weld interface comprises of thermal-mechanical affected zone (TMAZ), heat affected zone (HAZ) and welding zone (WZ) with varying thicknesses (i.e. 100 μm to 200 μm). It was also observed that Ti17 WZ is occupied by equiaxed β grains (mean size of 10 μm) with only one texture which was closely similar to {110} < 111 >. Whereas, Ti6242 WZ contained acicular α’ laths (1 μm) with two types of α texture. Ti17 HAZ + TMAZ were consisted of acicular α’ laths within refined equiaxed β grains and three types of texture of α and β, were respectively found in Ti17 HAZ + TMAZ zone. Whereas, Ti6242 HAZ + TMAZ zone was developed by elongated equiaxed α, acicular α’ laths and few β phases and only two types of texture of α and one type texture of β were found in this zone. The microstructural response across the joint concentrates plastic deformation in Ti6242 HAZ + TMAZ during fatigue cycle, which causes the fatigue fracture occurs at a radial distance of 150μm from the boundary between the Ti6242 TMAZ + HAZ and Ti6242 base metal.

Strength in Rotary Friction Welding of Five Dissimilar Nickel-Based Superalloys

Advanced manufacturing processes improve the cost and quality of goods. Rotary friction welding is a fast, energy-efficient, and reliable joining process for metals, but new applications are hindered by large development costs for each new alloy. Each alloy set has different welding characteristics; therefore, lessons learned from a single alloy are not always broadly applicable. To establish knowledge that is applicable across multiple alloys, a family of different superalloys were welded to discover process trends that were applicable beyond a single alloy set. In this study, weld symmetry did not correlate to weld strength across alloy systems. Some alloys’ strongest welds occurred at maximum symmetry, whereas high asymmetry was associated with different alloys’ maximum strength. High feed rates, high welding forces, low energy, and low temperatures all resulted in high-strength welds across all alloy and geometry combinations. Tensile strengths greater than 95% of base-metal strength were recorded for most alloy systems.

Döner Sürtünmeli Kaynak İşleminde Polipropilen Parçaların Birleşim Analizi ve Birleştirme Profilinin Geliştirilmesi

Various welding methods are used to produce non-detachable joints of plastic parts. These are friction welding (FW), friction-stir welding (FSW), ultrasonic welding, chemical bonding, and hot plate welding. Rotary friction welding (RFW) method, which is one of the FW methods, is generally used in joining the filter parts of water treatment devices. After RFW processes, semi-melted plastic accumulations tend to occur on the interior surfaces of the filter parts. In some cases, particles broken off from these accumulations can often clog sensitive filters. In this study, it is aimed to develop a welding joint profile design that can be used to confine the semi-melted agglomeration formed in the interior surfaces of the filter parts. For this purpose, the semi-melted agglomeration in the filter parts is analyzed/simulated utilizing the ABAQUS program by using Lagrangian and CEL (Coupled Eulerian-Lagrangian) methods, and their thermal analysis, stress, and energy data are evaluated. The analysis is repeated until the optimal welding structure design to confine the semi-melted agglomeration is developed. As a result of the analyses, it was determined that the maximum temperature reached is 166.2 °C, there was a 1.98 mm shortening in the length of the product after welding, and the temperature of 150 °C was reached in 13.1 milliseconds. From the several joint profile designs proposed, it was determined that the N3 joint profile design accommodates the semi-melt raw material better than the others.

A Critical Assessment on Rotary Friction Welded High Strength Armor Grade Aluminum Alloy Joints

A Critical Assessment on Rotary Friction Welded High Strength Armor Grade Aluminum Alloy Joints

Influence of Rotary Friction Welding Parameters on Tensile Strength and Length of TMAZ of Dissimilar Welded Joints from 32G2 and 40KhN Steels

In this work, pipe billets with a diameter of 73 mm and a wall thickness of 9 mm from steels 32G2 and 40KhN are friction welded with an aim to optimize the process parameters. The friction pressure, the forging pressure and the length of the fusion varied. After the implementation of various welding modes, tensile tests and metallographic studies were carried out. The optimal welding parameters have been established, which make it possible to obtain tensile strength at the level of the 32G2 base metal. The study results of the microstructure and SEM fractographs after the optimal welding mode are presented.

Investigation of interface microstructure and mechanical properties of rotatory friction welded dissimilar aluminum-steel joints

The objective of this work is to analyse the effect of variations in IMC thickness and microstructure at interface on the mechanical properties, for the RFW joints of Al6061 and mild steel. Rotary friction welding is a solid-state joining process which is advantageous towards joining of dissimilar materials. The rotary friction welding of Al6061 and mild steel is performed at combinations of two rotational speeds (1200 rpm and 1400 rpm) and three feed rates (10 mm/min, 20 mm/min and 30 mm/min). The microstructural characterization, tensile and hardness testing of the joints is performed. A concave joint interface is noticed due to inhomogeneous plastic deformation along the radial direction from center to workpiece periphery. Similarly, inhomogeneous intermetallic compounds formation along the radial direction at the joint interface is observed, with higher intermetallic compound thickness near the workpiece periphery. The grain refinement on Al6061 side of the interface is attributed to the continuous dynamic recrystallization. Dynamic recovery is noticed at the mild steel side. The crack initiates at the IMC rich region near the periphery and follows the IMCs to grow radially inwards. Along the radial direction from periphery to the center, the reduction in IMC thickness and increase in DRX region thickness resists the growth of the crack. Brittle failure is observed in the IMC rich regions near the periphery and ductile failure is noticed near the center. An increase in IMC thickness reduces the joint strength and wider DRX region improves the joint strength. This combination led to the maximum tensile strength for the joints prepared with intermediate feed rate of 20 mm/min. A maximum joint tensile strength of 136 MPa is achieved, which corresponds to 65 % joint efficiency.