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1
Ravendra, Jujavarapu Sai, and Palukuri Veerendra. "Studies on Effect of Tool Pin Profiles and Welding Parameters on the Friction Stir Welding of Dissimilar Aluminium Alloys AA5052 & AA6063." International Journal for Research in Applied Science and Engineering Technology 10, no. 4 (April 30, 2022): 3077–89. http://dx.doi.org/10.22214/ijraset.2022.41986.
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Abstract: Friction stir welding (FSW) is a solid-state joining process that uses the frictional heat generated by the rotating tool to soften the metals to form the joint. It is an effective technique for joining dissimilar aluminum alloys and finds its application in various fields such as aerospace and automotive industries. FSW process is energy efficient and environment friendly process. This FSW can produce joints with higher mechanical and metallurgical properties. Formerly, FSW was adopted for low melting metals like aluminum alloys. The various FSW parameters play a vital role in determining the quality of the welded joint. The parameters included in the study of different tool pin profiles (circular, pentagon and taper). FEA analysis will be performed for friction stir welding of Aluminum alloy 5052 and AA6063 at different tool pin profiles using ANSYS. This paper mainly focuses on studying the effect of different tool pin profiles on the microstructure and mechanical properties of the dissimilar AA5052 and AA6063 aluminum alloy joints. The weld quality characteristics like microstructure, micro-hardness, and tensile properties of the joints are analyzed and presented for three different tool pin profiles. It is observed from the result that the joint fabricated using three different tool pin profiles exhibits the better mechanical properties when compared to other joints. Index Terms: Friction stir welding, Aluminium alloys, AA5052, AA6063, Dissimilar welding.
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Syahrullail, Samion, Ahmad Mohd Azmi, Norzahir Sapawe, and Amir Khalid. "Wear Characterization of Aluminum Lubricated with Palm Olein at Different Normal Load." Applied Mechanics and Materials 554 (June 2014): 401–5. http://dx.doi.org/10.4028/www.scientific.net/amm.554.401.
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The pin-on-disk tester is a method used for investigating wear. The sliding mechanism between the pin and the disc experimentally creates wear. In this paper, the wear characteristics of an aluminium pin sliding on an SKD11 disc lubricated with double fraction palm olein were investigated. The pin was made from pure aluminum A1100. The results were compared with those of tests in which the disc was lubricated with commercial hydraulic oil. In both sets of experimental conditions, the normal load varied from 4 to 10 kg. Rotational speed was set to 1200 rpm. From this study, it was found that different types of lubricant affect the wear progression and friction coefficient during a sliding movement. The wear progression and friction coefficient depend also on the load applied, surface roughness, pressure applied and contact surface area.
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Mahmoud, Essam R. I., Sohaib Z. Khan, Abdulrahman Aljabri, Hamad Almohamadi, Mohamed Abdelghany Elkotb, Mohamed A. Gepreel, and Saad Ebied. "Free Intermetallic Cladding Interface between Aluminum and Steel through Friction Stir Processing." Crystals 12, no. 10 (October 6, 2022): 1413. http://dx.doi.org/10.3390/cryst12101413.
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In this paper, the cladding of pure aluminum and a low-carbon steel alloy was performed through friction stir processing with minimal intermetallic compound formation. A 3 mm thick aluminum plate was clamped on top of a steel plate. A thick, pure copper plate was used as a backing plate. The tool pin length was adjusted to be the same as the upper plate's thickness (3 mm) and longer than 3.2 mm. The effect of the tool pin length and the rotation speed (500–1500 rpm) on the cladding’s quality, microstructure, and the mechanical properties of the steel/aluminum interface were investigated using optical and scanning electron microscopy, a hardness test, and a peel test. The results showed that the bonding of pure aluminum and a low-carbon steel alloy can be successfully performed at a more than 500 rpm rotation speed. At a tool pin length of 3 mm and a rotation speed of 1000 rpm, sound and free-intermetallic compound–cladding interfaces were formed, while some Fel2Al5 intermetallics were formed when the rotation speed was increased to 1500 rpm. The pure copper backing plate has an essential role in eliminating or reducing the formation of intermetallic compounds in the cladding interface. When the tool pin length was increased to 3.2 mm, more steel fragments were found on the aluminum side. Moreover, with a higher rotation speed and longer tool pin length, more Fe2Al5 intermetallics were formed at the interface. Increasing the rotation speed and the pin tool length contributed to the enhancement of interface bonding. Meanwhile, the maximum tensile shear load was obtained at a rotation speed of 1500 rpm and a tool pin length of 3.2 mm. In addition, the hardness values of the interface were higher than the aluminum base metal for all the investigated samples. Decreasing the rotation speed and increasing the tool pin length can significantly increase hardness measurements. The average hardness increases from 42 HV of the pure aluminum to 143 HV at a rotation speed and a tool pin length of 1500 rpm and 3.2, respectively.
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Sukmana, Irza. "The Effect of Pin Shape on the Friction Stir Welding Quality of Aluminum AA1100 Series." Journal of Engineering and Scientific Research 4, no. 1 (June 28, 2022): 45–49. http://dx.doi.org/10.23960/jesr.v4i1.109.
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Aluminum is a material that is soft, lightweight, resistant to corrosion, and has good electrical and thermal conductivity. Aluminum has a specific gravity of about 2.65-2.8 kg/dm³, a melting point of 658ºC, and tensile strength of 90 MPa. Aluminum 1100 series is an aluminum alloy mixed with other materials, such as copper, iron, chrome, manganese, and zinc, with an aluminum content of 99,0%. Welding is the joining of two metals in a liquid state with or without filler. FSW (friction stir welding) is friction welding; the process does not require filler material. The heat used to melt the metal is obtained from the friction between the indenter and the workpiece. In the research, the shape of the indenter pin used is, ovale shape, cone shape, and changing spiral form with a tool rotation of 2000 rpm and a welding rate of 16 mm/minute. The tests carried out are Rockwell hardness testing and tensile tests. From the results of research conducted, it was found that the shape of the indenter pin greatly affects the quality of the weld. The indenter pin changing spiral form results in better weld quality compared to the other two pin shapes.
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TAKAHASHI, Keita, Yoshihiko HANGAI, Ryohei NAGAHIRO, Kenji AMAGAI, Takao UTSUNOMIYA, and Nobuhiro YOSHIKAWA. "Shaping of porous aluminum by pin screen." Proceedings of the Materials and processing conference 2018.26 (2018): 203. http://dx.doi.org/10.1299/jsmemp.2018.26.203.
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Zhang, Yunhe, Sian Wang, Xiwang Zhao, Fanming Wang, and Gaohui Wu. "In Situ Study on Fracture Behavior of Z-Pinned Carbon Fiber-Reinforced Aluminum Matrix Composite via Scanning Electron Microscope (SEM)." Materials 12, no. 12 (June 17, 2019): 1941. http://dx.doi.org/10.3390/ma12121941.
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Inside a scanning electron microscope (SEM) chamber, we performed an in situ interlaminar shear test on a z-pinned carbon fiber-reinforced aluminum matrix composite (Cf/Al) fabricated by the pressure the infiltration method to understand its failure mechanism. Experiments show that introducing a stainless-steel z-pin increases the interlaminar shear strength of Cf/Al composite by 148%. The increase in interlaminar shear strength is attributed to the high strength of the stainless-steel z-pin and the strong bonding between the z-pin and the matrix. When the z-pin/matrix interface failed, the z-pin can still experience large shear deformation, thereby enhancing delamination resistance. The failure mechanism of composite includes interfacial debonding, aluminum plough, z-pin shear deformation, frictional sliding, and fracture. These results in this study will help us understand the interlaminar strengthening mechanism of z-pins in the delamination of metal matrix composites.
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Verduzco Juárez, J. C., G. M. Dominguez Almaraz, R. García Hernández, and J. J. Villalón López. "Effect of Modified Pin Profile and Process Parameters on the Friction Stir Welding of Aluminum Alloy 6061-T6." Advances in Materials Science and Engineering 2016 (2016): 1–9. http://dx.doi.org/10.1155/2016/4567940.
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This work deals with the effect of a new “bolt-head” pin profile on the friction stir welding performance of the aluminum alloy 6061-T6, compared to traditional pin profiles. Friction stir welding parameters such as the tool rotation speed and the welding speed were investigated together with the different pin profiles; the results show that the new “bolt-head” pin profile leads to better mechanical properties of welded specimens. The pin profiles used in this work were the straight square (SS), straight hexagon (SH), taper cylindrical (TC), and the straight hexagon “bolt-head” (SHBH). It was found that the last pin profile improves the material flow behavior and the uniform distribution of plastic deformation and reduces the formation of macroscopic defects on the welded zone. Mechanical tensile tests on welded specimens were performed to determine the tensile strength: the specimens welded with the SHBH pin profile have shown the highest mechanical properties. An approach is presented for material flow on this aluminum alloy using the SHBH pin profile, which is related to the improvement on the resulting mechanical properties.
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Wang, Sian, Yunhe Zhang, Pibo Sun, Yanhong Cui, and Gaohui Wu. "Microstructure and Flexural Properties of Z-Pinned Carbon Fiber-Reinforced Aluminum Matrix Composites." Materials 12, no. 1 (January 7, 2019): 174. http://dx.doi.org/10.3390/ma12010174.
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Z-pinning can significantly improve the interlaminar shear properties of carbon fiber-reinforced aluminum matrix composites (Cf/Al). However, the effect of the metal z-pin on the in-plane properties of Cf/Al is unclear. This study examines the effect of the z-pin on the flexural strength and failure mechanism of Cf/Al composites with different volume contents and diameters of the z-pins. The introduction of a z-pin leads to the formation of a brittle phase at the z-pin/matrix interface and microstructural damage such as aluminum-rich pockets and carbon fiber waviness, thereby resulting in a reduction of the flexural strength. The three-point flexural test results show that the adding of a metal z-pin results in reducing the Cf/Al composites’ flexural strength by 2–25%. SEM imaging of the fracture surfaces revealed that a higher degree of interfacial reaction led to more cracks on the surface of the z-pin. This crack-susceptible interface layer between the z-pin and the matrix is likely the primary cause of the reduction of the flexural strength.
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Berber, Adnan, Kazım Bagirsakci, and Mehmet Gurdal. "Investigation of effects on heat transfer and flow characteristics of Cr-Ni alloy and aluminum pins placed in AISI 304 tube." Thermal Science 24, no. 3 Part B (2020): 1999–2011. http://dx.doi.org/10.2298/tsci180421306b.
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In this study, the effects of cylindrical aluminum and Cr-Ni alloy pins placed in different arrangements on the inner wall of the pipe in the turbulent flow, the effects of heat transfer and flow characteristics on different Reynolds numbers have been experimentally investigated. The experiments were carried out under forced flow and constant heat flow conditions. Air is preferred as the fluid and the fluid velocity is adjusted between Reynolds number of 10000 and 50000. It has been observed that the Nusselt values obtained over the number of Reynolds number for the 5 different test tubes are arranged in a line from large to small, sequential row aluminum pin, sequential row Cr-Ni alloy pin, diagonal row aluminum pin, diagonal row Cr-Ni alloy pin, plain tube. There are also CFD analysis for each material, arrangements and pins geometry sets. On the other hand, it was determined that friction coefficient is directly proportional to the increase of heat transfer coefficient. As a result, it is observed that experimental results are compatible with both literature and numerical study.
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Shojaeefard, Mohammad Hasan, Mostafa Akbari, Abolfazl Khalkhali, and Parviz Asadi. "Effect of tool pin profile on distribution of reinforcement particles during friction stir processing of B4C/aluminum composites." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 232, no. 8 (April 1, 2016): 637–51. http://dx.doi.org/10.1177/1464420716642471.
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Boron carbide /aluminum composites have been produced on an aluminum–silicon cast alloy using friction stir processing. Effect of pin profile on the distribution of boron carbide in the stir zone of the friction stir processed specimens was investigated experimentally and numerically. The material flow generated by the threaded and circular tool pin profiles, being the main reason for the distribution of particles in the metal matrix, was numerically modeled using a thermomechanically coupled three-dimensional finite element model. Numerical and experimental results show that threaded pin profile produces a more uniform distribution of B4Cp than other pin profiles. Hardness tests were performed in order to investigate mechanical properties of the composites. Wear resistance of the composite was evaluated and obtained results showed that the hardness and wear resistance of the composite significantly improved.
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Wang, Sian, Yunhe Zhang, and Gaohui Wu. "Interlaminar Shear Properties of Z-Pinned Carbon Fiber Reinforced Aluminum Matrix Composites by Short-Beam Shear Test." Materials 11, no. 10 (October 1, 2018): 1874. http://dx.doi.org/10.3390/ma11101874.
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This paper presents the effect of through-thickness reinforcement by steel z-pins on the interlaminar shear properties and strengthening mechanisms of carbon fiber reinforced aluminum matrix composites (Cf/Al) with a short beam shear test method. Microstructural analysis reveals that z-pins cause minor microstructural damage including to fiber waviness and aluminum-rich regions, and interface reaction causes a strong interface between the stainless steel pin and the aluminum matrix. Z-pinned Cf/Al composites show reduced apparent interlaminar shear strength due to a change in the failure mode compared to unpinned specimens. The changed failure mode could result from decreased flexural strength due to microstructural damage as well as increased actual interlaminar shear strength. Fracture work is improved significantly with a z-pin diameter. The strong interface allows the deformation resistance of the steel pin to contribute to the crack bridging forces, which greatly enhances the interlaminar shear properties.
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Kurokawa, Masaya, Yoshitaka Uchiyama, Tomoaki Iwai, and Susumu Nagai. "Tribological Properties of Polyoxymethylene Composites Against Aluminum." Journal of Tribology 125, no. 3 (June 19, 2003): 661–69. http://dx.doi.org/10.1115/1.1540123.
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Tribological properties of several kinds of polyoxymethylene (POM) composites were evaluated for the purpose of developing a polymeric tribomaterial especially suited for mating with aluminum parts having low surface hardness. POM composites containing small amounts of silicon carbide (SiC), POM/SiC; those containing a small amount of calcium octacosanonoate besides SiC, POM/SiC/Ca-OCA; and the one blended with 24 wt % of polytetrafluoroethylene, POM/PTFE(24); were injection-molded into pin specimens and their tribological properties were tested by means of a pin-on-disk type wear apparatus using an aluminum (A5056) mating disk in comparison with a 303 stainless steel (SUS303) disk. Evaluation was focused on observation of the sliding surfaces of the pin specimens and the mating disks by a scanning electron microscope and an optical microscope together with the measurement of surface roughness. In the case of mating against a SUS303 disk having high surface hardness, all pin specimens did not roughen the disk surfaces even after long time of rubbing. Only POM/PTFE(24) composite obviously made a transfer film on the disk surface, while the other composites made an extremely thin one on it. POM/SiC(0.1)/Ca-OCA(1) composite, containing SiC 0.1 wt. % and Ca-OCA 1 wt. %, was found to show the lowest coefficient of friction and the lowest wear rate forming extremely thin transfer film on the mating disk. On the other hand, against an A5056 disk which has lower surface hardness than that of SUS303 disk, unfilled POM and POM composites except POM/SiC(0.1)/Ca-OCA(1) composite roughened the disk surfaces. However, the sliding surface of the A5056 disk rubbed with POM/SiC(0.1)/Ca-OCA(1) composite was significantly smoother and that of the pin specimen was also quite smooth in comparison with other pin specimens. Further, when each POM composite was rubbed against the A5056 disk, formation of transfer film was not obvious on the disk surfaces. For POM/SiC(0.1)/Ca-OCA(1) composite, the wear rate was the lowest of all POM composites, and the coefficient of friction was as low level as 60 percent of that of unfilled POM, but slightly higher than that of POM/PTFE(24) composite. For POM/SiC(0.1)/Ca-OCA(1) composite, the nucleating effect of SiC and Ca-OCA, which accelerated the crystallization of POM during its injection molding to form a matrix containing fine spherulites, must have resulted in increasing the toughness of the matrix and lowering the wear rate. Also, the lubricant effect of Ca-OCA should have lowered the coefficient of friction of the same matrix for rubbing against aluminum mating disk. POM/SiC(0.1)/Ca-OCA(1) composite was concluded as an excellent tribomaterial for mating with aluminum parts.
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Hatzky, Marcel, and Stefan Böhm. "Extension of Gap Bridgeability and Prevention of Oxide Lines in the Welding Seam through Application of Tools with Multi-Welding Pins." Metals 11, no. 8 (July 30, 2021): 1219. http://dx.doi.org/10.3390/met11081219.
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Friction stir welding has become important in many areas of production and is increasingly used for joining aluminum components. For long welding seams, conventional tools with only one welding pin reach their technical limitations due to low gap bridgeability. When welding aluminum, the stirred in surface layers, such as oxides, lead to a decrease in static and dynamic strength since linear accumulations are formed in the welding seam. The aim of the present study is to increase the gap bridgeability using tools with various welding pins and to prevent linear accumulation in the welding seam. The results show that a gap bridgeability of up to 2 mm for 4 mm material thickness is possible for the aluminum alloys EN AW 5083 H111 and EN AW 7020 T651. With the help of multi-pin tools, no impact of the gap width on the tensile strength was observed for joint gaps of up to 0.9 mm when using butt joint with a sheet thickness of 4 mm. Furthermore, the use of multi-pin tools showed significant influence on the prevention of linear accumulations in the welding seam. In addition, the oxide layers were finely distributed in welded joints using multi-pin tools.
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Muzakki, Hakam, Ikrom Millaily, Ahmadi, Suwarsono, and Jefri S. Bale. "Macrostructure and Shear Strength Analysis on Cu-Al Joint of Micro Friction Stir Spot Welding." Key Engineering Materials 943 (March 29, 2023): 41–46. http://dx.doi.org/10.4028/p-xco4h9.
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Efficiency energy is an importance goal in transportation device development. Reducing weight of device is a way to reduce fuel consumption from transportation device, using thin plat in a device or construction could reduce the weight. The originality of this study was Micro Dissimilar Friction Stir Spot welding used to join Cu and Al plate with copper sheet on top the aluminum sheet. Micro welding is a joining thin plat less than 1 mm welded by Friction Stir Spot welding which has been called a Micro Friction Stir Spot welding, using a Pin on the Shoulder. Peak load average, macrostructure and shear strength of a copper and aluminum sheet joint welded by Micro Friction Stir Spot welding were discussed in this study. Copper and Aluminum 0.5 mm could be successfully joined. Shoulder diameter 6 mm effected to the highest peak load, and welding force 50 kgf significantly increased the peak load. Mixing Cu and Al formed in a weld joint. Friction was not complete occurred in shoulder interface and deflection copper sheet formed in around weld nugget because of Pin and Shoulder. A Pin on Shoulder affect to form a joint only around Pin, shear strength could not conclude because the weld joint areas developing tend to an incomplete joining.
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Wang, Lin Lin, and Xue Yuan Nie. "Investigation into Tribological Properties of TD-Treated D2 Steel for Applications in Dry Machining of Aluminum Alloy." Advanced Materials Research 314-316 (August 2011): 263–66. http://dx.doi.org/10.4028/www.scientific.net/amr.314-316.263.
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This research is to investigate tribological properties of thermal diffusion (TD) treated D2 steels against aluminum (Al 6061) counterface material for its potential applications in dry machining/forming of aluminum composite materials. A hard vanadium carbide (VC) layer was formed on the tool steels by the TD process. Original D2, thermal treatment hardened D2 and TiN coating on hardened D2 were used as references. Pin-on-disc tribo-tests were performed on those samples against Al pins under a dry sliding condition. Wyko profilemetry analysis showed that Al pin material transferred to the D2, hardened D2 and TiN coating surface and caused adhesive wear, which may negatively influence product quality in machining/forming applications. The TD-VC coating on D2 steel has a good adhesive wear resistance and anti-sticking of aluminum performance, which is a promising material used for dry machining/forming of aluminum.
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Winarto, W., M. Anis, and B. Eka Febryansyah. "Mechanical and Microstructural Properties of Friction Stir Welded Dissimilar Aluminum Alloys and Pure Copper Joints." MATEC Web of Conferences 269 (2019): 01001. http://dx.doi.org/10.1051/matecconf/201926901001.
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Joining dissimilar metal alloys such as aluminum and copper is very difficult to be done because of alterations in chemical, metallurgical and physical behavior. Friction Stir Welding (FSW) is a solid-state welding technique which is one of the new methods used for joining the dissimilar metal. The material used is aluminum alloy 5052 and pure copper plates. The welding parameters were carried out with variable geometry shape of pin tools: taper and threaded cylindrical pin tools. Also preheating were performed on the part of copper plates with temperatures at both 25°C and 200°C. The friction stir welding of dissimilar joints was carried out at the rotary tool speed of 2800 rpm with the angle of 1 degree and the welding travel speed of 2 mm/sec. All welds were then carried out to several mechanical testing and microscopic observation. The results show that the variable geometry shape of pin tools and pre-heating on the copper part affect the microstructure grain size and the formation of Al-Cu inter-metallic phases. The creation of different structures influences the mechanical properties of the friction stir welds. The hardness of welds using threaded pin tools is higher than the tapper one. However, the tensile strength of dissimilar welds using the threaded cylindrical pin tools is lower than the tapper one. The fracture location commonly occurs at the part of aluminum plates having a brittle intermetallic phase.
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Gan, Wen Ying, Zheng Zhou, Li Xin Wang, and Yong Gang Wu. "Texture Evolution of Friction-Stir-Welded 5A30 Aluminum Alloy Plate." Applied Mechanics and Materials 599-601 (August 2014): 136–39. http://dx.doi.org/10.4028/www.scientific.net/amm.599-601.136.
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In the present study, the texture of friction-stir-weled 5A30 aluminum alloy was investigated by EBSD technology. Cubic texture {100}<100> is obtained in the shoulder-affected region of NZ due to the complete recrystallization. The dominate texture in the pin-affected region of NZ is the {112}<110> B/ simple shear texture induced by the rotation pin.
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Nadikudi, Bhanodaya Kiran Babu. "Effect of friction stir welding tool profiles on mechanical properties of dissimilar welded aluminum alloy plates." International Journal of Structural Integrity 12, no. 4 (March 8, 2021): 562–68. http://dx.doi.org/10.1108/ijsi-10-2020-0097.
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PurposeThe main purpose of the present work is to study the effect of tool pin profiles on mechanical properties of welded plates made with two different aluminium alloy plates.Design/methodology/approachThe welded plates were fabricated with the three different kinds of pin profiled tools such as taper cylindrical, taper threaded cylindrical and stepped cylindrical pin profiles. Tensile properties of welded plates were evaluated using tensile testing machine at room temperature. Microstructures studies were carried out using scanning electron microscope.FindingsTensile properties were improved with the use of taper threaded cylindrical pin tool in friction stir welding process when compared with taper cylindrical and stepped cylindrical pin tools. This is due to refinement of grains and mixing of plasticized material occurred with generation of sufficient heat with the taper threaded pin tool. Through these studies, it was confirmed that friction stir welding can be used to weld Al6061 and Al2014 aluminium alloy plates.Research limitations/implicationsIn the present study, the friction stir welding is performed with constant process parameters such as tool rotational speed of 900 rpm, transverse speed of 24 mm/min and tilt angle of 1°.Practical implicationsAluminium alloys are widely using in automotive and aerospace industries due to holding a high strength to weight property. These aluminium alloy blanks can be developed with friction stir welding method with better properties.Originality/valueVery limited work had been carried out on friction stir welding of aluminium alloys of Al 6061 and Al2014 with different tool pin profiles. Furthermore, this work analyzed with tensile properties of welded plates correlated with weld zone microstructures.
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Ramesh, R., S. Suresh Kumar, and R. V. Srinivasan. "Effect of Process Parameters on Mechanical Characterization of Dissimilar Friction Stir Welded Aluminium Alloys." Applied Mechanics and Materials 766-767 (June 2015): 701–4. http://dx.doi.org/10.4028/www.scientific.net/amm.766-767.701.
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Aluminum alloys exhibit poor weldability by conventional fusion welding process. The heat treatable aluminum alloy AA2014 is extensively used in the aircraft industry because it has good ductility and high strength to weight ratio. In this paper the effects of welding parameters and tool profile on the mechanical properties of friction stir welded butt joints of dissimilar aluminum alloy sheets AA6082 and AA2014. The process parameters such as rotational speed, transverse speed and axial forces were considered. The effect of parameters on weld quality was analyzed. Hardness and tensile tests are carried out at room temperature to examine the mechanical properties of the welded joints. The joints produced with straight square tool pin profile have higher ultimate tensile strength, whereas the straight cylindrical tool pin profile results in lower tensile strength.
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Izzati, Tiya. "THE EFFECT OF HEAT TREATMENT AND SURFACE ANODIZATION ON FRICTION AND WEAR COEFFICIENT OF ALUMINIUM 2024 USING PIN ON DISK METHOD." Metalurgi 37, no. 1 (June 23, 2022): 1. http://dx.doi.org/10.14203/metalurgi.v37i1.620.
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The use of aluminum alloys as a material for engineering components that rub against each other is increasing, so it is important to know the friction characteristics of these aluminum alloys. In this study, Aluminum 2024 was given heat treatment with variation in aging time and anodization. Then, the wear and friction coefficient tests were carried out using a pin tool on the disc. The effect of aging time and surface anodization on wear tests are carried out to determine the amount of wear and the coefficient of friction test is carried out to determine the coefficient of friction of the material when it rubs against a pin made of AISI 52100 Steel. The coefficient of friction test is carried out by adding lubrication as a parameter. The test results showed that the aluminum material given heat treatment had better resistance than that which was not heat treated. This is because the heat treatment creates precipitates that can increase the aluminum's hardness and wear resistance. Whereas for anodized specimens, the alumina layer can act as an abrasive grain when given a high enough friction and load continuously, so the wear testing mode changes from dry sliding wear to three body abrasive wear and decreased wear resistance. From the friction coefficient test results, the aging time affects the hardness of the aluminum alloy, which leads to the value of the coefficient of friction. The harder the sample surface, the smaller the coefficient of friction obtained. Furthermore, applying lubricant to the sample will also decrease the value of the friction coefficient of the sample. Lubricating oil will provide a more significant reduction in friction coefficient than air. Finally, the anodizing surface on the sample will act as a lubricant reservoir when it occurs.
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Sekar, K., and P. Vasanthakumar. "Microstructural Evaluation of Similar and Dissimilar Welding of Aluminum Metal Matrix Hybrid Composite by Friction Stir Welding." Materials Science Forum 979 (March 2020): 124–28. http://dx.doi.org/10.4028/www.scientific.net/msf.979.124.
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To address the challenges of reducing the CO2 emission in automotives, Aluminum metal matrix hybrid composites have been extensively used in automotive and aerospace industries for the fabrication of light weight structure. Huge demand in joining dissimilar metals increased day by day, because it reduces the weight and cost of components by utilizing hybrid structures. The friction stir welding is adopted for dissimilar AA5754 rheo-squeeze cast (RSC) with AA7075 stir casted hybrid composite. Micro sized B4C and nanosized Al2O3 are reinforced into this material. Friction stir welding of these alloys by varying the tool material, pin and shoulder profiles, rotational speed, tool traverse speed and tilt angle. Microstructure of the joint are studied and inferences drawn are presented. The better welding was obtained with triangular and square pin profile when compared to cylindrical pin whereas triangular pin profile was more better than square pin. Tapered shoulder possessed greater strength, which resulted in a good weld in contrast to flat shoulder. The high carbon high chromium steel (HCHCr) tool exhibited a higher tool wear rate than stainless steel (SS) tool and found to be an appropriate one to weld aluminum hybrid composite.
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Manikandan, Venugopal, M. A. Joseph, and P. K. Rajendrakumar. "Dry sliding wear studies of aluminum matrix hybrid composites." Resource-Efficient Technologies, no. 5 (December 22, 2016): S12—S24. http://dx.doi.org/10.18799/24056529/2016/5/82.
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In the present work, hybrid composites are fabricated with self-lubricating characteristics to make them as resource-efficient materials.AA6061-10 wt. % B4C–MoS2 hybrid composites reinforced with 2.5, 5 and 7.5 wt. % concentration of MoS2 particles are produced using stircasting technique, and mechanical and tribological properties are evaluated. Microstructural characterization of the hybrid composites revealed theuniform distribution of reinforcement (B4C and MoS2) particles in the matrix material. Hardness and fracture toughness of the hybrid compositesare decreased monotonously with an increase in the addition of MoS2 particles. Dry sliding tribological studies conducted using a pin-on-disktribotester under atmospheric conditions revealed the formation of MoS2-lubricated tribolayer on the worn pin surface which significantlyinfluenced the tribological properties. The addition of MoS2 particles decreased the friction coefficient and wear rate of the hybrid composites.Delamination and abrasion are observed to be the controlling wear mechanisms and material in the form of platelet-shaped debris, and flow-typechip debris is formed, and a long and shallow crater on the worn pin surface of the hybrid composite is also observed.
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Chobaomsup, Viriyah, and Luangvaranunt Tachai. "Effect of Aluminum Addition to Cu-10wt%Sn Bearing on its Pin-on-Disc Wear Behavior." Advanced Materials Research 154-155 (October 2010): 1296–300. http://dx.doi.org/10.4028/www.scientific.net/amr.154-155.1296.
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The objective of this research was to study effect of sintering time, sintering temperature and aluminum addition on pin-on-disc wear behavior of Cu-10wt%Sn bearing that was produced from powder metallurgy method. It was found that, for the as-sintered samples, the larger addition of aluminum, the greater reduction in density and hardness in all sintering conditions. Density and hardness of samples sintered at 900°C decreased with increasing sintering time. Density and hardness of samples sintered at 830°C increased with increasing sintering time. Maximum hardness was obtained when the samples were sintered at 900°C for 30 min or sintered at 830oC for 60 min. Heat treating the samples by annealing at 750oC for 1 h, and quenching in water improved the hardness of the samples alloyed with aluminum significantly. Hardness of 5wt%Al sample increased by 37% to 69.2 HV. Wear mode of samples without aluminum addition was abrasive with accumulation of α-phase wear debris on worn pin surface. For samples with aluminum addition, wear mode was abrasive-oxidative producing clean worn surface which was preferred for self-lubrication mechanism of this type of bearing.
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Singh, Gagandeep, Khushdeep Goyal, Baljinder Ram, and Bal Krishan. "Microstructural Characterization and Mechanical Properties in Friction Stir Welding of AA6061 and AA6101 Aluminum Alloys." Advanced Engineering Forum 40 (April 2021): 1–11. http://dx.doi.org/10.4028/www.scientific.net/aef.40.1.
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In this research paper, two different metal plates of aluminum alloy viz. AA6061 and AA6101 were welded with friction stir welding process. Round tool and square tool pin profiles were used to weld the alloys. Weld microstructures, hardness, and tensile properties were evaluated in as-welded condition. The tensile strength of the joints fabricated with round tool pin profile were lower than the square tool pin profile because of the pulsating effect, in square tool pin profile this effect was produced along with the higher frictional forces. The micro-hardness of friction stir zone was higher than the base material due to active recrystallization occurrence which resulted in fine grain size in case of weld joint with round pin profile. Microstructure indicated uniformly distribution of materials with minimum heat affected zone and dense welded zone without any defects.
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SETIAWAN, WIDIA, BERNADO PASARIBU, MUHAMMAD BADARUDIN THOHA, GUSTI KETUT PUDJA, NUGROHO SANTOSO, and ISWORO JATI. "DISIMILLAR LAP JOINT FRICTION STIR WELDING (FSW) USING VARIED LENGTH OF PIN." MM Science Journal 2021, no. 6 (December 15, 2021): 5340–45. http://dx.doi.org/10.17973/mmsj.2021_12_2021121.
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The lap joint will be used on aluminum 6061 and 10 mm thick brass with the Friction Stir Welding method. The probe used is EMS 45 steel with variations in pin lengths of 11 mm, 11.5 mm and 12 mm. The results of this study are in length 11.5 mm with the highest Vickers hardness value of 104.26 VHn compared to 11 mm and 12 mm pin length is 98.93 VHn and 70.43 VHn. The results of shear stress are 67.32 MPa at 12 mm pin length, higher than the 11 mm and 11.5 mm pin lengths of 40.2 MPa and 42.14 MPa.
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Palanivel, R., P. Koshy Mathews, M. Balakrishnan, I. Dinaharan, and N. Murugan. "Effect of Tool pin Profile and Axial Force on Tensile Behavior in Friction Stir Welding of Dissimilar Aluminum Alloys." Advanced Materials Research 415-417 (December 2011): 1140–46. http://dx.doi.org/10.4028/www.scientific.net/amr.415-417.1140.
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Aluminium alloys generally has low weldability by traditional fusion welding process. The development of the Friction Stir Welding (FSW) has provided an alternative improved way of producing aluminium joints, in a faster and reliable manner. FSW process has several advantages, in particular the possibility to weld dissimilar aluminium alloys. This study focuses on the behavior of tensile strength of dissimilar joints of AA6351-T6 alloy to AA5083-H111 alloy produced by friction stir welding was analysed. Five different tool pin profile such as Straight Square (SS), Tapered Square (TS), Straight Hexagon (SH), Straight Octagon (SO) and Tapered Octagon (TO) with three different axial force (1tonne, 1.5tonne, 2 tonne) have been used to weld the joints. The effect of pin profiles and axial force on tensile properties and material flow behaviour of the joint was analyzed and it was found that the straight square pin profile with 1.5 tonne produced better tensile strength then other tool pin profile and axial force.
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Chupradit, Supat, Dmitry Olegovich Bokov, Wanich Suksatan, Michał Landowski, Dariusz Fydrych, Mahmoud E. Abdullah, and Hesamoddin Aghajani Derazkola. "Pin Angle Thermal Effects on Friction Stir Welding of AA5058 Aluminum Alloy: CFD Simulation and Experimental Validation." Materials 14, no. 24 (December 9, 2021): 7565. http://dx.doi.org/10.3390/ma14247565.
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The friction stir welding (FSW) of tool pin geometry plays a critical role in the final properties of the produced joint. The tool pin geometry directly affects the generation of heat and the flow of internal materials during the FSW process. The effects of the FSW tool pin angle on heat generation and internal flow have not been quantitatively investigated in detail. In this manuscript, a validated Computational Fluid Dynamic (CFD) model was implemented to analyze the effects of pin angle on the thermo-mechanical action during the FSW process of AA5058 Al-Mg alloy. Experimental test results validate the thermal outcomes of the used model. The obtained results revealed that, when the pin angle is increased, the heat generation decreases while the mechanical action of the tool increases. The internal heat distribution at a higher pin angle is symmetrical. The higher mechanical action of the tool decreases the viscosity of the internal materials and increases stirring action (materials flow) around the pin. Furthermore, plastic flow near the tool increased stirring action and formed a larger stir zone in the joint area.
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Abdel-Gwad, Ebtisam F., A. Shahenda, and S. Soher. "Effect of Friction Stir Welding Parameters on Thermal and Tensile Behavior of Aluminum Weldments Using Double Shoulder Tools." Advanced Materials Research 622-623 (December 2012): 323–29. http://dx.doi.org/10.4028/www.scientific.net/amr.622-623.323.
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Friction stir welding (FSW) process is a solid state welding process in which the material being welded does not melt or recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters and tool pin profile play major roles in deciding the weld quality. In this investigation, an attempt has been made to understand effects of process parameters include rotation speeds, welding speeds, and pin diameters on al.uminum weldment using double shoulder tools. Thermal and tensile behavior responses were examined. In this direction temperatures distribution across the friction stir aluminum weldment were measured, besides tensile strength and ductility were recorded and evaluated compared with both single shoulder and aluminum base metal.
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Helal, Yazid, and Zakaria Boumerzoug. "PIN DIAMETER EFFECT ON MICROSTRUCTURE AND MECHANICAL PROPERTIES OF DISSIMILAR FRICTION STIR LAP WELDING ALUMINUM ALLOY 6061-T6 TO DUAL PHASE STEEL." Acta Metallurgica Slovaca 24, no. 2 (June 28, 2018): 163. http://dx.doi.org/10.12776/ams.v24i2.1049.
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<p class="AMSmaintext"> </p><p class="AMSmaintitle">Abstract</p><p class="AMSmaintext">In this work, the effect of the pin diameter on the microstructure, hardness and strength of friction stir welded 6061-T6 aluminum alloy to dual phase steel have been investigated. Microhardness measurements, tensile shear tests, optical microscopy, and scanning electron microscopy with energy dispersive spectroscope (EDS) were the main techniques used. The results showed that friction stir welding can be used for the joining of dissimilar 6061-T6 aluminum alloy to dual phase steel. We have found that the maximum strength is obtained after welding with the highest pin diameter. </p>
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García-Vázquez, Felipe, Benjamín Vargas-Arista, Rodrigo Muñiz, Juan Carlos Ortiz, Héctor Hernández García, and Jorge Acevedo. "The Role of Friction Stir Processing (FSP) Parameters on TiC Reinforced Surface Al7075-T651 Aluminum Alloy." Soldagem & Inspeção 21, no. 4 (December 2016): 508–16. http://dx.doi.org/10.1590/0104-9224/si2104.10.
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Abstract: Aluminum alloys are very promising for structural applications in aerospace, military and transportation industries due to their light weight, high strength-to-weight ratio and excellent resistance to corrosion. In comparison to unreinforced aluminum alloys, aluminum/aluminum alloy matrix composites reinforced with ceramic phases exhibit higher strength and hardness, improved tribological characteristics. A novel surface modifying technique, friction stir processing (FSP), has been developed for fabrication of surface composite with an improved performance. The effect of FSP parameters such as number of passes, direction of each pass, sealed or unsealed groove on microstructure was investigated. In this work, nano-particles of TiC (2% in weight) were added to aluminum alloy AA7075-T651 to produce a functional surface. Fixed parameters for this AA7075 alloy were used; rotation speed of 1000 rpm, travel speed of 300 mm/min and pin penetration of 2.8 mm. Optical microscopy (OM), scanning electron microscopy (SEM) and atomic force microscopy (AFM) were employed to study the microstructure of the fabricated surface composites. The results indicated that the selected FSP parameters influenced the area of surface composite, distribution of TiC particles and micro-hardness of the surface composites. Finally, in order to evaluate rate wear the pin on disk test was carried out.
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Verma, Shubham, Meenu Gupta, and Joy Prakash Misra. "Effect of pin-profiles on thermal cycle, mechanical and metallurgical properties of friction stir–welded aviation-grade aluminum alloy." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 233, no. 11 (February 22, 2019): 2183–95. http://dx.doi.org/10.1177/0954405419832109.
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Current research is an attempt to choose suitable pin-profile for friction stir welding of aviation-grade aluminum alloy (AA6082). Six tool pin-geometries (T1–T6), that is, threaded cylindrical, taper cylindrical, four slotted, square, triangular and inverted tapered with two flat faces are used to fabricate joints. Mechanical and metallurgical properties of the joints are assessed and allied with nugget zone grain size and thermal properties. The swept volume ratio and pulsating-stirring action of pin-profiles are also quantified. It is observed that square pin-profile provides joint with superior mechanical and metallurgical properties owing to higher pulsating-stirring action and sufficient swept volume ratio. The maximum tensile strength of 300 MPa is obtained by employing square pin-profile tool. Beside this, electron backscatter diffraction analysis has been conducted to critically examine the effect of pin-profiles on grains distribution of nugget zone of friction stir–welded joints. The minimum grain size of 5.48 μm is obtained using square pin-profile.
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Morales, Cindy Estefanía, Argelia Fabiola Miranda, Gladys Yerania Pérez, and Eduardo Hurtado. "Evaluation of discontinuities in friction stir welds of aluminum matrix composites." Aircraft Engineering and Aerospace Technology 90, no. 7 (October 1, 2018): 1065–71. http://dx.doi.org/10.1108/aeat-01-2017-0024.
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Purpose The purpose of this paper is to evaluate the welding quality of the friction stir joints of Al-SiC with diverse shape of pin geometry tools. Design/methodology/approach Aluminum matrix composites are gaining unlimited interest and special position in aeronautical industry because of their properties enhanced by the presence of ceramic reinforcement, such as lower density, dimensional stability, exceptional wear and abrasion resistance. Friction stir welding arises as a promising welding process with more advantages than traditional fusion process in the joining of aeronautical components with the utilization of a non-consumable rotational tool shaped by a shoulder and a pin, which can be designed in as many possible geometries. However, the welding quality is not always achieved when varying these pin configurations. Findings The fabrication and implementation of different pin geometry tools to weld the plates of the material allows to study the behavior of the joints assessing some discontinuities produced in the welds. Practical implications To examine the microstructural evolution and its behavior in the different zones of the joint, the practical implication consists in the use of different characterization techniques like the optic microscopy and scanning microscopy, furthermore mechanical test such as the measurement of hardness. Originality/value The study of the joints uses different welding tool geometries that were fabricated at prototype scale contribute in the microstructural analysis as well as in the evaluation of the possible discontinuities that are presented.
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Chen, Yu, He Wang, Huaying Li, Xiaoyu Wang, Hua Ding, Jingwei Zhao, and Fenghe Zhang. "Investigation into the Dissimilar Friction Stir Welding of AA5052 and AA6061 Aluminum Alloys Using Pin-Eccentric Stir Tool." Metals 9, no. 7 (June 26, 2019): 718. http://dx.doi.org/10.3390/met9070718.
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Friction stir welding with different pin-eccentric stir tools (the pin eccentricities were 0, 0.4, and 0.8 mm, respectively) was successfully utilized for joining dissimilar aluminum alloys AA5052 and AA6061, and the influences of pin eccentricity on the microstructural evolution and mechanical properties of joints were investigated. The results showed that sound joints could be obtained by placing the hard AA6061 in the advancing side, while the welding heat input led to both the coarsening of strengthening precipitates and dynamic recrystallization and softening of the nugget zone (NZ). The application of pin eccentricity promoted the material flow in the NZ and enlarged the area of the “onion ring”. Furthermore, the average grain size and fraction of recrystallized grain in the NZ decreased as the pin eccentricity increased. All joints failed in the NZ during tensile tests, and the joint produced by the 0.8 mm-pin-eccentric stir tool performed the highest tensile strength due to the enhanced grain-boundary and dislocation strengthening.
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Guo, Zheng Hua, Gang Yao Zhao, Li Ming Ke, Li Xing, and Shun Feng Zhu. "Finite Element Analysis of Materials Flow Behavior in Friction Stir Welding of 7075 Aluminum Alloy Plate." Applied Mechanics and Materials 117-119 (October 2011): 1621–24. http://dx.doi.org/10.4028/www.scientific.net/amm.117-119.1621.
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A 3D elastic-plastic and coupled thermo-mechanical FE model for friction stir welding(FSW) of 7075 aluminum alloy plate was developed based on the dynamic explicit code ABAQUS/explicit, then the FSW process of 7075 aluminum alloy plate was simulated and the materials flow behavior was analyzed. The results show that in the horizontal direction of the plate, two patterns of materials migration are produced: (1) the material rotates with the tool and finally deposits the tentative cavity behind the pin; (2) the material transfers in the mode of laminar flow. Furthermore, the streamlines of material in advanced side (AS) are bent along the reverse welding direction. After bypassing the pin, the material of retreating side (RS) moves backward it, and extends to AS.
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Syahrullail, Samion, and Noorawzi Nuraliza. "Friction and Wear Performance of Double Fraction Palm Olein Lubricant Using Pin-on-Disk Tribometer." Applied Mechanics and Materials 554 (June 2014): 396–400. http://dx.doi.org/10.4028/www.scientific.net/amm.554.396.
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In the present of analysis, the wear rate and friction coefficient of various material is investigated and it were compared below the result of sliding speed wherever the equipment pin on disk machine has been used. Experiments were carried out with 2 totally different pins fabricated from aluminum alloy (AA5083) and pure aluminum (A1100). Experiments were conducted at normal load in step with according to testing, 10 N with totally different sliding speed 1, 3, 5 m/s ,continuous flow lubricating substance, double fraction palm olein (DFPO). The result shows that the material from pure aluminum higher material compared to the aluminum alloy in sliding condition. The morphology of the worn surface was ascertained using high optical research. The magnitude of the friction constant and wear rate are totally different in material depending on the speeds and additionally material.
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Azhagar, Arunagiri, Kunio Hayakawa, Hiroo Shizuka, and Katsuhiko Sakai. "Influence of Tool pin Profiles in Friction Stir Welding of Aluminum Alloy and Polycarbonate." Defect and Diffusion Forum 414 (February 24, 2022): 185–90. http://dx.doi.org/10.4028/p-ohtn3n.
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In this study, the impact of tool pin profile on the dissimilar joining characteristics of aluminum alloy AA2017 and polycarbonate in friction stir welding (FSW) was examined. The tool pins made of SKD11 tool steel were used in the experiments of the FSW to join AA2017 and polycarbonate plates in a butt configuration at a tool rotation speed of 1320 and 1760 rpm and tool transverse speed of 60 mm/min. The tool shoulder diameter and tool pin height were set to 10 mm and 2 mm. The shapes of tool pin were cylindrical with and without groove, tapered cylindrical with and without groove, bobbin shaped with and without groove, square, triangular, pentagonal, hexagonal, oval, and ellipsoidal. The measurement of axial force was performed using a dynamometer. The changes in workpiece temperature at six locations during the process were measured using K-type thermocouples embedded in the plates. Microstructures of welded joints were examined by an optical microscope. Vickers Microhardness mapping was performed in and around the weld nugget zone, which is formed by the material flow between the two different base materials. From the result, the grooved tool pins generated less heat; while cylindrical, square, and oval type pins are also result in the superior properties of the welds during joining processes. Each tool pin had unique material flow behavior and weld formation, and the weld defects such as tunnel/voids occurred at the joint interface. The oval tool pin gives rise to the highest joint efficiency at a higher tool rotation speed, and the ellipsoidal tool pin generates the highest joint efficiency at a lower tool rotation speed was noticed.
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Ramesh, Nallavelli, and K. Palaksha Reddy. "Effect of Operational Parameters on AA2014 Friction Stir Weldments Using Plain Cylindrical Tool." Applied Mechanics and Materials 592-594 (July 2014): 216–23. http://dx.doi.org/10.4028/www.scientific.net/amm.592-594.216.
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Aluminum alloys are mostly used for high strength structural applications utilized in aircraft structure, trucks body, military vehicles, bridges and weapons manufacture. Conventional fusion welding of aluminum alloy produces porosity and hot cracks in the welded joint due to incorrect selection of consumables and parameters, which may lead to lower weld toughness and defects in the mechanical properties. The mostly adopted method for welding AA 2014-T6 is solid state joining process. Friction stir welding (FSW) is an emerging solid state of joining process which avoids bulk melting of the basic material, hot cracking and porosity. The welding parameters and tool pin profile play a major role in deciding weld quality. In this investigation, an attempt has been made to understand the various influences of tool rotational speed, welding speed and pin profile of the tool on friction stir processed (FSP) zone formation in joining of AA2014 aluminum alloy. High Carbon High Chromium steel tool of plain cylindrical pin profile is used to fabricate the joints. The average grey relation grade for each level of each factor are calculated and it was found that the optimal settings of the levels of factors Tool rotation speed (A), Weld speed (B) and Tilt angle (C) are A1-B3-C3. The findings from these investigations will be presented and discussed.
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Bokov, Dmitry Olegovich, Mohammed Abed Jawad, Wanich Suksatan, Mahmoud E. Abdullah, Aleksandra Świerczyńska, Dariusz Fydrych, and Hamed Aghajani Derazkola. "Effect of Pin Shape on Thermal History of Aluminum-Steel Friction Stir Welded Joint: Computational Fluid Dynamic Modeling and Validation." Materials 14, no. 24 (December 20, 2021): 7883. http://dx.doi.org/10.3390/ma14247883.
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This article studied the effects of pin angle on heat generation and temperature distribution during friction stir welding (FSW) of AA1100 aluminum alloy and St-14 low carbon steel. A validated computational fluid dynamics (CFD) model was implemented to simulate the FSW process. Scanning electron microscopy (SEM) was employed in order to investigate internal materials’ flow. Simulation results revealed that the mechanical work on the joint line increased with the pin angle and larger stir zone forms. The simulation results show that in the angled pin tool, more than 26% of the total heat is produced by the pin. Meanwhile, in other cases, the total heat produced by the pin was near 15% of the total generated heat. The thermo-mechanical cycle in the steel zone increased, and consequently, mechanical interlock between base metals increased. The simulation output demonstrated that the frictional heat generation with a tool without a pin angle is higher than an angled pin. The calculation result also shows that the maximum heat was generated on the steel side.
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Saxena, Pragya, Arunkumar Bongale, Satish Kumar, and Priya Jadhav. "Investigation of microstructural and wear behavior of Al6061 surface composites fabricated by friction stir process using Taguchi approach." Materials Research Express 9, no. 1 (January 1, 2022): 016522. http://dx.doi.org/10.1088/2053-1591/ac4a2d.
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Abstract The surface composites of aluminum alloys have a higher scope of applications encountering surface interactions in the aerospace, automobile, and other industries compared to the base aluminum alloys. The friction stir process (FSP) is recently the preferred method to prepare aluminum-based surface composites due to its capability to produce improved physical properties and refined microstructure at the surface. The study examines the Al6061 alloy-based surface composite fabricated by FSP for their wear behavior and microstructure. In this study, the Al6061 alloy-based hybrid surface composites are prepared with varying weight% of copper and graphite microparticles mixture as reinforcement by FSP with two tools having unique pin profiles, i.e., threaded cylindrical and plain cylindrical. These prepared composites are investigated for the dry sliding wear test on a pin-on-disc test set-up. The experiments are designed using the L9 orthogonal array and analyzed by the Taguchi approach to obtain the influence of disc speed, load, and reinforcement weight% on wear rate. The significant parameters influencing the wear rate of the samples tested are obtained using ANOVA. Later the effects of the friction stir process and the wear tests on the microstructure of the workpieces are investigated using FE-SEM/EDS tests. It is concluded that the decrease in wear rate with the rise in reinforcement weight% (Cu + graphite) from 2% to 6%. The load has the maximum effect on the wear rate for the samples prepared by threaded cylindrical FSP tool pin profile, while reinforcement weight% affects significantly the wear rate of the samples prepared by FSP with plain cylindrical pin profile tool.
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Lacki, P., A. Derlatka, and T. Gałaczyński. "Selection of basic position in Refill Friction Stir Spot Welding of 2024-T3 and D16UTW aluminum alloy sheets." Archives of Metallurgy and Materials 62, no. 1 (March 1, 2017): 443–49. http://dx.doi.org/10.1515/amm-2017-0068.
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Abstract One of the important parameters of Refill Friction Stir Spot Welding is the so-called basic position of the tool. This is the arrangement of the pin and sleeve which occurs when the tool is plunged into the material. The basic positions can be divided into two categories. In the first category, the sleeve and the pin are above the sheet surface or below sheet surface and in the second category the pin is retracted within the sleeve or protrudes from it. The aim of the work was to test four settings of the basic position, and then determine the best setting of the basic position, without changing the other welding parameters. Joints made of an aluminum alloy 2024-T3 sheet having a thickness of 1.0 mm and an aluminum alloy D16UTW sheet having a thickness of 0.6 mm were analysed. The best setting of the basic position was determined based on assessment of the force carried in shear test, macrostructure and weld face of the joints.
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Miranda, G., M. Buciumeanu, MM Costa, F. Bartolomeu, FS Silva, and O. Carvalho. "Metallic reinforcements role on aluminum silicon composites wear behavior." Journal of Composite Materials 51, no. 19 (November 13, 2016): 2805–12. http://dx.doi.org/10.1177/0021998316678052.
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This study is concerned with the influence of four metallic reinforcements on aluminum-silicon (AlSi) composites, with respect to wear behavior. AlSi-Ti; AlSi-Ti6Al4V; AlSi-1.4301 stainless steel and AlSi-Ni particulate reinforced composites were produced by a hot-pressing route. Microstructural characterization showed a uniform distribution of the reinforcing particles in the AlSi matrix. Reciprocating pin-on-plate wear tests were performed for AlSi and AlSi-based composites against gray cast iron plates. In order to compare the effect of different metallic particulates on the AlSi-based composites/gray cast iron tribopair wear performance, besides the pin, the counterface was also analyzed. The particle/matrix interface is analyzed in order to understand its influence on the tribopair behavior and on the controlling wear mechanisms. It was shown that the better compromise between both sliding surfaces performance was attained by AlSi-Ni/gray cast iron tribopair.
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Lee, Ho Sung, Jong Hoon Yoon, and Joon Tae Yoo. "Effect of Rotating Tool Geometry on Mechanical Properties of Friction Stir Welded Aluminum Alloy 2195." Key Engineering Materials 783 (October 2018): 132–36. http://dx.doi.org/10.4028/www.scientific.net/kem.783.132.
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It is known that Al-Li alloys show high specific strength and have been used in space vehicles with Friction stir welding (FSW). FSW has many advantages including the absence of porosity, low distortion and reduced residual stresses which are typical defects of the fusion welding processes. The process uses a rotating tool with a profiled pin that penetrates the parts to be welded. The tool starts to travel along the welding line and the softened material due to the frictional heat is stirred and mechanically mixed together by the rotating pin forming a weld in solid state without melting. Welding parameters such as tool rotational speed, travelling speed, and tool geometry are the main parameters which affect the material flow and the heat generation rate. The important tool geometry includes pin size and shape, pin tread and pitch, tool materials, and shoulder size and shape. The present work is to study the effect of tool geometry on the microstructure and mechanical properties of friction stir welded aluminum alloy 2195. Five different tool profiles have been used to investigate the effects of tool geometry on mechanical properties. The experimental results show that aluminum alloy 2195-T8 can be welded using FSW process with maximum welding efficiency of 75% using threaded cylindrical with concave shoulder at rotation speed, 600 RPM and welding speed, 300 mm/min.
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Ahmed, Mohamed M. Z., Kamel Touileb, Mohamed M. El-Sayed Seleman, Ibrahim Albaijan, and Mohamed I. A. Habba. "Bobbin Tool Friction Stir Welding of Aluminum: Parameters Optimization Using Taguchi Experimental Design." Materials 15, no. 8 (April 9, 2022): 2771. http://dx.doi.org/10.3390/ma15082771.
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This work aims to optimize the performance evaluation characteristics such as the temperature at the weld center of the lap joint (Tw), the tensile shear load (TSL), and the hardness using an experimental design experiment for bobbin tool friction stir welding (BT-FSW) of AA1050 lap joints. BT-FSW is characterized by a fully penetrated pin and double-sided shoulder that promote symmetrical solid-state welds. This study contributes to improving the quality of 10 mm thick lap joints and addressing challenges to obtaining a sound weld deprived of any defects. Taguchi L9 orthogonal array (OA) experimental design was performed. Three different pin shapes (cylindrical, triangular, and square) and three levels of welding travel speeds of 200, 400, and 600 mm/min were selected as input controllable process parameters at a constant tool rotation speed of 600 rpm. A travel speed of 200 mm/min with square pin geometry significantly improves the TSL of the joint up to 6491 N. However, the hardness characteristic is optimized by using 600 mm/min travel speed and a cylindrical tool pin. The minimum temperature in the weld joint can be obtained using 600 mm/min or more with triangular pin geometry. From ANOVA results, it was seen that the BT-FSW of AA 1050 thick lap joints performance in terms of TLS and Tw were greatly influenced by travel speed; however, the tool shape influences the hardness more. For the validation of the models, BT-FSW experiments have been carried out for AA1050 using the applied processing parameters. Furthermore, regression models were developed to predict the Tw, TSL, and hardness. The calculated performance properties from the mathematical models were in an acceptable range compared to the measured experimental values.
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Карпенко, Дмитрий Валерьевич, and Валентина Васильевна Цыганова. "The Effect of Aluminum Oxide Nanoparticles on the Activity of Amylases of the Enzyme Preparation of Microbial Origin." Beer and beverages, no. 4 (December 12, 2021): 6–10. http://dx.doi.org/10.52653/pin.2021.4.4.008.
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На основании анализа литературных данных показано, что изучение влияния наночастиц, в том числе оксида алюминия, на активность целевых ферментов микробных ферментных препаратов, применяемых в пивоваренном производстве, целесообразно. Приведены данные о влиянии наночастиц Al2O3 на процесс гидролиза крахмала в модельных средах под действием амилаз ферментного препарата «АПСубтилин П». Показано, что присутствие наночастиц в реакционной среде приводит к снижению амилолитической активности и, как следствие, снижению концентрации редуцирующих веществ в гидролизате на 12-15% (при содержании наночастиц 0,1 мг/см3) и на 34% (при содержании наночастиц 1,0 мг/см3) по сравнению с контролем. Установлено, что увеличение продолжительности ферментативного гидролиза с 60 до 120 мин приводит к ослаблению ингибирующего воздействия наночастиц Al2O3 на амилолитическую активность ферментного препарата. При этом присутствие наноразмерных объектов указанного типа не оказало негативного воздействия на результаты лабораторного затирания, проводимого по настойному способу с тремя паузами: основные показатели первого сусла опытных вариантов не уступали аналогичным характеристикам контрольного образца. На основании приведенных данных сделано заключение о нежелательности присутствия наночастиц Al2O3 в реакционных средах амилаз микробного происхождения в концентрациях, превышающих 0,1 мг/см3. The expediency of studying the effect of nanoparticles, in particular, aluminum oxide, on the activity of target enzymes of enzyme preparations used in brewing is substantiated based on the analysis of the literature data. Data on the effect of Al2O3 nanoparticles on the process of starch hydrolysis in model media under the action of amylases of the enzyme preparation «APSubtilin P» are presented. It has been shown that the presence of nanoparticles in the reaction medium leads to a decrease in amylolytic activity and, as a consequence, a decrease in the concentration of reducing substances in the hydrolyzate by 12-15% (at nanoparticle content of 0.1 mg/cm3) and by 34% (at nanoparticle content of 1, 0 mg/cm3) compared to the control. It was found that the increase in the duration of enzymatic hydrolysis from 60 to 120 min leads to a weakening of the inhibitory effect of Al2O3 nanoparticles on the amylolytic activity of the enzyme preparation. At the same time, the presence of nanoscale objects of this type did not have a negative impact on the results of laboratory mashing, carried out according to the infusion method with three pauses: the main indicators of the first wort of the experimental variants were not inferior to those of the control sample. Based on the data presented, it was concluded that the presence of Al2O3 nanoparticles in the reaction media of amylases of microbial origin in concentrations exceeding 0.1 mg/cm3 is undesirable.
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Wakchaure, Kiran N., and A. G. Thakur. "Mathematical and experimental examination of the effect of the stepped pin tool profile on the characterization of AA 6061-T6 underwater friction stir welding." Metallurgical and Materials Engineering 28, no. 4 (December 31, 2022): 593–624. http://dx.doi.org/10.56801/mme869.
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This research paper presents the mathematical model to design a stepped pin profile tool and its durability index. A mathematical model is being developed by considering tools that should generate the same heat as conventional conical tools and stepped tools by varying the shoulder to pin diameter ratio (D/d). Aluminum alloy AA6061-T6 with a thickness of 6 mm fabricated using a butt-type weld configuration and newly developed conical stepped pin profile tools with water as a cooling medium. The result shows that a conical stepped tool shows better mechanical properties of the welded joints compared with a conventional conical tool. When compared to other stepped conical pin profile tools, one with a (D/d) of 3 has superior mechanical and microstructural properties and as the D/d ratio increases, the tool pin durability index falls.
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Kaushik, Narinder, Sandeep Singhal, Rajesh Rajesh, Pardeep Gahlot, and B. N. Tripathi. "Experimental investigations of friction stir welded AA6063 aluminum matrix composite." Journal of Mechanical Engineering and Sciences 12, no. 4 (December 27, 2018): 4127–40. http://dx.doi.org/10.15282/jmes.12.4.2018.11.0357.
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The advancement of friction stir welding for joining of aluminum alloys and aluminum centered matrix composite has replaced the traditional welding techniques. In this experimental study, AA6063/10.5wt%SiC composite has been produced by employing enhanced stir casting technique with the assistance of Mg metal powder. Specimen composite plates having thickness 6 mm were friction stir welded successfully. The impact of welding variables on mechanical and microstructural characteristics of weldments has been studied. The friction stir welding (FSW) was carried out at a rotation rate of tool of 1400 rpm with a tool transverse rate of 124 mm/min. A cylindrical tool fabricated of high-speed steel (HSS) with square pin shape has been used for FSW. The results revealed that the ultimate tensile strength of the welded joint was 163 MPa, which was very close to the strength of the as-cast composite matrix. The microstructural study showed the reason for higher joint strength and microhardness. The welded butt joint exhibited a change in the microstructure at various four welding zones which transforms the mechanical characteristics of welded joints has been due to the asymmetrical flow of material and thermal cycles around the pin. The intense stirring action of the tool pin during FSW cracked the SiC particles in the weld nugget. In the weld region, a fine-grained structure and homogeneous dispersion of SiC particles have been observed. The micro porosities associated with the base metal composite matrix were eliminated after FSW.
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Othman, Nurul Hidayah, Norsyahfiana Abdul Razak, Luqman Hakim Ahmad Shah, and Mahadzir Ishak. "Effect of Taper Pin Ratio on AA7075 Aluminium Alloy Friction Stir Welding." Key Engineering Materials 701 (July 2016): 154–58. http://dx.doi.org/10.4028/www.scientific.net/kem.701.154.
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This study focuses on the effect of pin taper tool ratio on friction stir welding of aluminum AA7075. Two pieces of AA7075 alloy with thickness of 6 mm were friction stir welded by using conventional milling machine. The shoulder diameter used in this experiment is fix 18mm. The taper pin ratio used are varied at 6:6, 6:5, 6:4, 6:3, 6:2,and 6:1. The rotational speeds that were used in this study were 1000 rpm, 1200 rpm and 1400 rpm, respectively. The welding speeds used are 60 mm/min, 80 mm/min and 100 mm/min. Microstructure observation of welded area was studied by using optical microscope. To evaluate the mechanical properties of this specimen, tensile test was used in this study. Welded specimens using taper pin ratio 6:2 shows higher tensile strength compared to other taper pin ratio up to 197 MPa. Moreover, taper pin ratio 6:1 showed better tensile test compared to taper pin ratio above 6:3. The optimum parameters were found to be taper pin ratio 6:2 with 1000 rpm of rotational speed and 60mm/min welding speed.
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Vairis, Achilles, Markos Petousis, Nikolaos Mountakis, Charikleia Tsarouchidou, and Nectarios Vidakis. "The Effect of Tool Geometry on the Strength of FSW Aluminum Thin Sheets." Materials 15, no. 22 (November 18, 2022): 8187. http://dx.doi.org/10.3390/ma15228187.
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Welding tools of different designs have been used to join friction stir welding 2-mm-thick Al 7075 sheets, to investigate the effect of the tool geometry on the weld performance. Five cylindrical tools with different pin geometries were manufactured from heat-treatable low alloy steel WNr 1.6582/DIN 34CrNiMo6. Additionally, the effect of the welding speed was considered in the work, with six different speeds ranging from 80 mm/min to 300 mm/min. The weld tool rotational speed was kept constant at 1000 rpm and all other parameters were also kept constant in the experiments. The tensile strength was measured to investigate the mechanical properties of the weld. Results were processed with statistical analysis tools, which showed that the mechanical strength was affected by tool geometry as well as welding speed. The weld tool with the highest pin diameter achieved the highest tensile strength. The welding speed affected the tensile strength differently in the different weld tool geometries studied. The highest weld efficiency reported in the tests is 72.20%, achieved with a cylindrical pin weld tool at 250 mm/min.
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Ahmed, Shoaib, Rana Atta ur Rahman, Awais Awan, Sajjad Ahmad, Waseem Akram, Muhammad Amjad, Mohd Yazid Yahya, and Seyed Saeid Rahimian Rahimian Koloor. "Optimization of Process Parameters in Friction Stir Welding of Aluminum 5451 in Marine Applications." Journal of Marine Science and Engineering 10, no. 10 (October 19, 2022): 1539. http://dx.doi.org/10.3390/jmse10101539.
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Friction stir welding (FSW) is one of the primary fabrication techniques for joining different components, and it has become popular, especially in aluminum alloy structures for marine applications. The welded joint with the friction stir process greatly depends on the process parameters, i.e., feed rate, rotational speed, and pin profile of the tool. In the current study, plates of aluminum 5451 alloy were joined by the FSW technique, and the Taguchi method was used to find the process parameters at an optimal level. The maximum value of tensile strength, i.e., 160.6907 MPa, was achieved using optimum welding conditions of a tool rotation speed of 1400, a feed rate of 18 mm/min, and the tool pin with threads. The maximum value of hardness, i.e., 81.056 HV, was achieved using optimum conditions of 1200 tool rotational speed and a feed rate of 18 mm/min with a tool pin profile having threads. In addition, the contribution in terms of the percentage of each input parameter was found by the analysis of variance (ANOVA). The ANOVA results revealed that the pin profile of the tool has the maximum contribution of 67.77% and 62.42% in achieving the optimum value of tensile strength and hardness, respectively. The study also investigated the joint efficiency of the friction stir welded joint, hardness at the weld zone, and metallography on FSW samples at the optimized level. The effectiveness and reliability of FSW joints for shipping industry applications can be observed by joint efficiency. That was investigated at optimum conditions, and it comes out to be 80.5%.
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Ahmed, Mohamed M. Z., Mohamed I. A. Habba, Mohamed M. El-Sayed Seleman, Khalil Hajlaoui, Sabbah Ataya, Fahamsyah H. Latief, and Ahmed E. EL-Nikhaily. "Bobbin Tool Friction Stir Welding of Aluminum Thick Lap Joints: Effect of Process Parameters on Temperature Distribution and Joints’ Properties." Materials 14, no. 16 (August 15, 2021): 4585. http://dx.doi.org/10.3390/ma14164585.
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Bobbin tool friction stir welding (BT-FSW) is characterized by a fully penetrated pin and double-sided shoulder that promote symmetrical solid-state joints. However, control of the processing parameters to obtain defect-free thick lap joints is still difficult and needs more effort. In this study, the BT-FSW process was used to produce 10 mm AA1050-H14 similar lap joints. A newly designed bobbin tool (BT) with three different pin geometries (cylindrical, square, and triangular) and concave shoulders profile was designed, manufactured, and applied to produce the Al alloy lap joints. The experiments were carried out at a constant tool rotation speed of 600 rpm and a wide range of various welding travel speeds of 200, 400, 600, 800, and 1000 mm/min. The generated temperature during the BT-FSW process was recorded and analyzed at the joints’ center line, and at both advancing and retreating sides. Visual inspection, macrostructures, hardness, and tensile properties were investigated. The fracture surfaces after tensile testing were also examined. The results showed that the pin geometry and travel speed are considered the most important controlling parameters in BT-FSW thick lap joints. The square (Sq) pin geometry gives the highest BT-FSW stir zone temperature compared to the other two pins, cylindrical (Cy) and triangular (Tr), whereas the Tr pin gives the lowest stir zone temperature at all applied travel speeds from 200 to 1000 mm/min. Furthermore, the temperature along the lap joints decreased with increasing the welding speed, and the maximum temperature of 380 °C was obtained at the lowest travel speed of 200 mm/min with applying Sq pin geometry. The temperature at the advancing side (AS) was higher than that at the retreating side (RS) by around 20 °C. Defect-free welds were produced using a bobbin tool with Cy and Sq pin geometries at all the travel welding speeds investigated. BT-FSW at a travel speed of 200 mm/min leads to the highest tensile shear properties, in the case of using the Sq pin. The hardness profiles showed a significant effect for both the tool pin geometry and the welding speed, whereas the width of the softened region is reduced dramatically with increasing the welding speed and using the triangular pin.