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ABSTRACT

The friction welding of dissimilar material combinations such

as Al 6061 - SS 304, Al 5052 – SS 304, Pure Al – SS 304, Al 6061 –

copper, pure Al – copper are very important. As some of these weld

combinations are used in very critical applications such as

aerospace, nuclear power plants, cryogenics, rocket fuel systems,

electrical and automotive applications. Therefore the weld strength

and its interface properties are extremely important. The failure of

these parts can lead to huge losses.

The friction welding of these dissimilar materials is more

complicated compared to similar materials due to differences in

physical, mechanical, chemical and thermal properties. The

problems associated with friction welding of aluminum and its alloys

to SS 304 and copper are lower weld strength in the inner region,

susceptibility to formation of intermetallic compounds, formation of

unbond zone at the inner region (central portion), presence of oxides

layers at the weld interfaces, non uniform heat generation across the

weld interface, unsymmetrical deformation with respect to the plane

of the joint interface and large amount of material consumption

during welding process.

In friction welding with regular joint geometry (flat face to flat

face), the heat generated in inner region is lower than outer region.

This is because of lower rotation speed of inner region (central

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portion) when compared to outer region. The heat generation

decreases radially as distance from centre to outer periphery of the

work piece decreases. Therefore welding starts from the outer

periphery and it progresses to inner region, which increases the

severity of previously mentioned problems.

Due to progression of welding from outer region to inner

region, the oxides and other contaminations are entrapped in the

inner region (center portion) of weld interface. The temperature

developed in the inner region is not enough to destroy or remove the

oxides and other contaminations from the inner region. This problem

is more severe due to unsymmetrical deformation with respect to the

plane of the joint interface.

Due to lower temperature and entrapped oxides in the inner

region, unbound zone is formed at the inner region. If the inner

region temperature is increased by increasing the heating time then

the outer region is overheated and it lead to intermetallic compounds

formation. As the formation of intermetallic compounds, strongly

depends on weld interface temperature.

In the present research the friction welding process is

improved by reversing the progression of welding. The reversing of

progression of welding is achieved by designing a new joint

geometry. In new joint geometry, welding is started from the inner

region and it progresses to outer region.

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The shape of new joint geometry helps in uniform heat

generation at the weld interface.

The burs formation and shape of new joint geometry facilitate

in destruction and removal of oxides and other contaminations from

the inner region of weld interface.

The uniform temperature, removal of oxide layer, and

progression of welding from inner region to outer region, helps in

preventing the unbound zone at the inner region of the weld

interface.

The weld strength is evaluated by tensile test and bend test. It

was observed that the weld strength of new joint geometry is more

than regular joint geometry. The strength of inner region is

evaluated by half size tensile specimen. It is observed that the tensile

strength of half size tensile specimen of new joint geometry is more

than regular joint geometry.

The material consumption in new joint geometry is 46% to

56% less than regular joint geometry. Thus helps in material and

cost saving. Generally these weld combinations are used as

transition joint are they are required on mass scale therefore the

new joint geometry leads to good amount of saving.

It was observed that the weld interface temperature of new

joint geometry is less than regular joint geometry. Thus helps in

reducing intermetallic compound formation and heat affected zone.

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The microstructure analysis is carried out for new and regular

joint geometry to analyze the microstructural changes occurred

during friction welding process. It was observed that new joint

geometry helps in prevention or reduction of intermetallic

compounds during friction welding process. Excellent contact was

observed in new joint geometry without any defects. A very fine grain

size is observed in Al 6061 near the weld joint and the grain size

decreases as the distance from the weld line decreases.

A very fine grain size is observed in Al 6061 near the weld

joint and grain size decreases as the distance from the weld line

decreases. There is negligible change in microstructure of SS 304.

The variation of intermetallic layer thickness across the weld

interface follows the heat generation pattern except at the periphery.

The thickness of intermetallic layer in regular joint geometry is

minimum at the centre and it increases radially as distance from

centre of the weld interface increases (along the weld line) and at the

periphery it again decreases as the intermetallic compound squeezes

out during forging phase. In new joint geometry either no

intermetallic compounds are formed or a very thin intermetallic layer

of almost uniform thickness is formed at weld interface.

X-Ray diffraction technique is used to identify the

intermetallic compounds formed at weld interface. In welding of Al

6061 to copper the intermetallic compounds found at weld interface

are Al2Cu3, AlCu4 and CuAl2 and in welding of Al 5052 to SS 304 the
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intermetallic compounds formed at the weld interface are FeAl2 and

AlFe.

Hardness analysis is carried out to analyze the variation of

hardness due to large strains and temperature at the weld interface.

Increase in hardness was observed near the weld interface and it is

due plastic deformation and grain size reduction. Hardness values

gives information about the metallurgical changes caused by welding.

Design of experiment (DOE) is used to characterize the

friction welding process for Al 6061 to SS 304. The experimental data

for each of the responses are analyzed using analysis of variance

(ANOVA) to identify the significant contributing factors. Main Effect

plots are studied to understand the influence of different weld

parameters (rpm, friction pressure, friction time, upset pressure and

upset time) on responses (tensile strength, upset and temperature).

Interaction plots are studied to understand whether the effect of a

one factor depends on the level of the other factor.

Mathematical model is developed to predict weld strength,

upset and weld interface temperature in terms of weld parameters.

The influence of upset and temperature on weld strength are

investigated. Acceptance criteria are established for friction welding

of Al 6061 to SS 304 for online monitoring of friction welding process

using data acquisition system.

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In friction welding, it was observed that, the optimum selection

of weld parameters such as rpm, friction pressure, friction time,

forging pressure and forging time are not sufficient to achieve sound

weld but selection of proper upset condition like application of upset

pressure in constant feed or rapid feed and application of upset

pressure (0.6 second) before braking or after braking are extremely

important, without this sound weld cannot be achieved. The effect of

upset conditions on yield strength, ultimate tensile strength,

material consumption and temperature for aluminum alloy to SS 304

is investigated.

A finite element model was developed using ANSYS and

Abaqus software to predict the weld interface temperature and

stresses. The temperature predicted by FE model helps in controlling

intermetallic compound formation. Maximum temperature predicted

for weld combination of Al6061-SS304 is 223.89 °C. Maximum stress

observed at weld interface is 115 MPa.

Further, new friction spot welding process with new joint design

is developed to overcome the problems associated with friction stir

spot welding process and refill friction stir spot welding process. The

new friction spot welding process with new joint design improves the

weld strength and it prevents defects which are common in friction

stir spot welding and refill friction stir spot welding process. It was

observed that the shear strength of new friction spot welding of Al

sheet to steel sheet with steel filler material was more than
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conventional friction stir spot welding process. The shear strength of

new friction spot welding process with steel as filler material was 3.5

KN where as the shear strength of convention friction stir spot welding

process was 2.45 KN. This enhancement of weld strength is due to

direct welding of steel sheet to steel filler material, interlocking feature

of new design, large contact area and effective removal of oxides layer

from the weld interface. The proposed new joint design and welding

process is best suitable for welding of two incompatible (non weldable)

sheets with a filler material which is weldable with both the sheets.

This proposed process could also be best suitable for replacement of

riveting process for automotive, aerospace, and other critical

applications.