Proceedings of First International Conference on Energy and Environment: Global Challenges

March 09 & 10, 2018

Department of Chemical Engineering, National Institute of Technology Calicut, Kozhikode, Kerala, India.

Experimental Investigation of Friction Welding on Aluminium AA5083

Alloy
Gurunath Shinde1,2*, Sarafaraj Mulani2,Pradip Gunavant2,Abhijeet Suryawanshi2,Prakash Dabeer3
1
Research Scholar, Department of Mechanical Engineering, G.H.Raisoni College of Engineering & Management, Pune.
2
Asst. Professor, Department of Mechanical Engineering, Dr.Daulatrao Aher College of Engineering, Karad, India
3
Professor, Department of Mechanical Engineering, Trinity College of Engineering. and Research, Pune, India

*Corresponding author email: gurunathshinde@yahoo.com

ABSTRACT

In this paper effect of rotary friction welding on similar joints of aluminum AA5083 was investigated. Initially some
trials were conducted with due consideration of material shrinkage. Successful joint was obtained when material
shrinkage is less i.e. less material removal. Tensile strength and microstructure were further observed. All samples were
failed at weld region except one which was failed at parent material showing tensile strength of weld is more than parent
material.

Keywords – Rotary Friction Welding, Tensile Strength, Microstructure.

1. INTRODUCTION (CP-Al) and austenitic stainless steel (AISI 304).The

Friction welding is one of the solid-state welding
processes which involve plunging one component
relative to the other component by generating required
amount of heat and then applying lateral force
(upsetting force) to plastically displace and fuse
materials. Friction welding is not actually a welding
process in the traditional sense as no melting occurs, but
it’s a forging technique (Fig.1). However, due to the
similarities between these techniques and traditional
welding, the term has become common. Friction
welding does not require filler materials. Hence, the
properties won’t be altered to a great extent and the
weld doesn’t have any inclusions and gas porosity as
compared to any other type of welding. Also, it is a
very fast process because of which heat affected zone in
the base metal is much less when compared to other
welding processes. The weld obtained will also have
greater strength than that of the other welding process.
100% metal to metal contact can be achieved using
friction welding.
Fig.1.Basic Concept of Rotary Friction Welding
(RFW)
2. LITERATURE REVIEW
Kimura et al [1] described the effect of friction welding
condition on joining phenomena, tensile strength, and
bend ductility of friction welded joints between pure Al
joint, which had high joint efficiency, the fracture on
the CP-Al side with no crack at the weld interface, and
no IMC interlayer on the weld interface, could be
successfully achieved. Liang et al [2] carried out study
on 5A33 aluminum alloy bar with AZ31B magnesium
alloy bar by continuous drive friction welding. The
tensile strength of the joints increased with increasing
friction time and on average the highest strength could
reach up to 101 MPa when friction time was 5s.All the
friction welded samples failed at the friction interface
during tensile test. Shinde et al[3] have done review of
friction welding on different materials and their weld
ability. Successful weld joints are obtained at optimal
parameter values. Improper weld parameters led to
defects and failure of the joints. Some numerical
approaches are also used to predict the process
mathematically. Friction welding can be successfully
applied to aluminum, mild steel, stainless steel, Cast
Iron and some non metallic materials etc. Applications
of friction welding are automotive, aerospace, defense,
marine, refineries etc. Pandia Rajan et al [4] carried out
to weld two dissimilar materials of SA 213 tube to SA
387 tube plate using an external tungsten carbide tool to
enhance and validate the mechanical and metallurgical
properties. It was observed that the optimal joint
strength for the work piece without hole and with hole
are 3062 MPa and 2845 MPa respectively. The value of
Vickers hardness test was found in the welded zone to
be much greater in work piece without hole that the
work piece with hole are 313 Hv and 283 Hv
respectively. Gavade et al [5] presented work deals

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with, effect of friction welding process parameters like Table 2: Physical Properties of AA5083
friction pressure, friction time, and rotational speed on
mechanical properties such as tensile strength, hardness Property Value
and fatigue strength of aluminum 6061-T6 alloy.
Density 2650 kg/m3
friction pressure and rotational speed are significantly
contributing towards friction welding performance Melting Point 570 °C
Therefore; most influencing parameters are friction
pressure and rotational speed for optimizing mechanical Modulus of Elasticity 72GPa
properties. The second influencing parameter is friction
time. Friction pressure, friction time and rotational Electrical Resistivity 0.058 x 10Ω.m
speed have a significant effect on tensile strength,
Thermal Conductivity 121 W/mK
hardness and fatigue strength. Mechanical properties
like tensile strength, fatigue strength and hardness of Thermal Expansion 25 x 10-6/k
friction welded joints found less than base metal
strength. Selvamani et al [6] conducted study on 12mm Table 3: Fabrication Response of AA5083
diameter AISI1035 grade steel rods with an aim to Property Value
optimize the process parameters. The joints are made
Density 2650 kg/m3
with various process parameter combinations subjected
to tensile test. Rotational speed was found to have Melting Point 570 °C
greater influence on tensile strength of the joints
followed by Forging pressure and Friction pressure. The Modulus of Elasticity 72GPa
Vickers’s micro hardness of the weld zone has
increased at 59.7% of the base metal. Electrical Resistivity 0.058 x 10Ω.m

Thermal Conductivity 121 W/mK

3. EXPERIMENTAL DETAILS Thermal Expansion 25 x 10-6/k

A. Material Selection:
Rotary Fiction Welding was carried out on joints B. Rotary Welding Set up:
between similar Aluminum AA 5083 alloy. Dimensions The 5 trials were initially carried out on continuous
used for AA5083 are 18 mm diameter and 70 mm long. drive friction welding machine FWT T-12 machine.
The chemical composition of the base materials is The round specimens of 18mm diameter and 70 mm
presented in Table 1.Physical properties of the base long were prepared on simple lathe machine. During the
materials are presented in Table 2.Fabrication Response welding process one specimen was kept stationery and
of AA5083 is shown in table 3. other is rotated. The stationery specimen is then pushed
towards rotating specimen with large axial force.
Table 1: Chemical Composition of AA5083 Frictional heat causes softening of material and when
other specimen is pushed both the specimen are
Eleme
Si Fe Cu
M
Ni Ti Cr Sn Pb
attached together by formation of flash as shown in
nt n fig.2.

% Pres 0.74 0.33 0.0 0.5 0.02 0.008 0.00 0. 0.

2 5 4 3 5 07 31
ence 8

Elem A
Ca Di Zr V CO CD PL
ent L

% 0.0 0.0 0.0 0.0 0.0 0.0 0.0 97

Pres 003 02 009 06 005 01 002 .9
ence

Fig.2.Stages of Rotary Friction Welding

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C. Welding Conditions: 4. RESULTS

Here we carried 5 trials of Similar Aluminum
AA5083 Alloy. During the welding RPM, Friction
Pressure, Feed, Upset Time, Friction Time and
Shrinkage Range were kept constant. The experiments
were carried out by changing the upset pressure
(Kg/mm2).
Table 4. Experimental Details of welded joint
Five specimens are coded as D39, D40, D41, D42 and
D43 as shown in Fig.4.Tensile Strength of all the 5
samples was carried out. All the samples were failed at
the weld region as shown in fig.5 showing weld
strength is poor than parent material while D41 piece is
failed at the parent material showing strength of the
weld is more than parent material.

Job D39 D40 D41 D42 D43

RPM 1600 1600 1600 1600 1600

Feed 0.85 0.75 0.75 0.75 0.75

mm/min.

Upset 40 30 35 25 20
Pressure
kg/mm2

Friction 17 10 10 10 10
Fig. No.5.Specimens after Tensile Test
Pressure
Sample D39 was failed at load of 88.9 kN and tensile
Upset Time 3 3 3 3 3 strength of the weld is 316.88 N/mm2.Sample D40 was
failed at load of 38.68 kN and tensile strength of the
Upset Delay 0.1 0.6 0.1 0.1 0.1 weld is 137.58 N/mm2.Sample D41 was failed at load
of 96.3 kN and tensile strength of weld is 343.25
N/mm2.Sample D42 was failed at load of 87.92 kN and
Break Delay 0.6 0.1 0.6 0.6 0.6
tensile strength of weld is 313.71 N/mm2.Sample of
D41 of dimensions 18 X 10 mm was prepared for the
Friction 0.6 0.5 0.5 0.5 0.5
micro structural analysis as shown in Fig.6.
Time Microstructure of D41 was observed by scanned
electron microscope (SEM) at 400X resolution as
Shrinkage 5.16 5.16 5.16 5.16 5.16 shown in fig.7.
Range

Fig.6.Cross Section of D41

Fig.4.Specimens after welding

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Fig.7.Microstructure of D41
Kellers Reagent etchant was used for surface
preparation of cross section of D41 sample. Micro
structural analysis shown particles of Mg2Si (Black) in
matrix of aluminum solid solution.
5. CONCLUSION
Rotary Fiction Welding was carried out on joints
between similar Aluminum AA 5083 alloy. The 5 trials
were initially carried out on continuous drive friction
welding machine FWT T-12 machine. Sample D39 was
failed at load of 88.9 kN and tensile strength of the weld
is 316.88 N/mm2.Sample D40 was failed at load of
38.68 kN and tensile strength of the weld is 137.58
N/mm2.Sample D41 was failed at load of 96.3 kN and
tensile strength of weld is 343.25 N/mm2.Sample D42
was failed at load of 87.92 kN and tensile strength of
weld is 313.71 N/mm2.
ACKNOWLEDGEMENTS
We are thankful to the Principal, Vice-principal and
Management of AGTI’s Dr.Daultrao Aher College of
Engineering, Karad for providing financial support to
carry out the work.
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Yang, Xiangmeng Meng “Continuous drive friction
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