MICROSTRUCTURE CHARACTERIZATION AND MECHANICAL

PROPERTIES OF AA6061 ALLOY AND BRASS ALLOY JOINT USING

ROTARY FRICTION WELDING
Dr.Uday M Basheer Al Naib1,* and Nor Iskandar Kassim Maniam

Faculty of Mechanical Engineering,

Universiti Teknologi Malaysia,
81310 UTM Johor Bahru, Johor Bahru,
Malaysia

ABSTRACT

Rotary friction welding is used for joining of round part like engine valve, steering rod, shaft and other parts in
aerospace application. Rotary friction welding process is solid state joining approach hence limitation of fusion
welding of joining different material of different melting point overcome using friction welding. In this friction
welding process despite of different melting point both AA6061 and copper alloy joined which was not feasible
earlier by fusion welding process. The rotary friction welding (RFW) process in particular is attracting
increasing interest for the high quality joining of circular and tubular components. RFW, as it's known, is a
non-fusion process in which the material reaches a hot plastic state during the welding cycle. Aerospace
industry use Aluminium alloy as primary material for structure and frame due to its light weight and
mechanical properties. Hence Aluminium alloy is selected as one material for this research work. Also, in
aerospace, automobile, marine, defense equipment appliances for joining various copper alloy electrical parts
to Aluminium part. Mainly, in aerospace structure part made up of Aluminium alloy and various other metals
parts to be joined to Aluminium alloy part using friction welding.

Keyword: Rotary friction welding, non-fusion process, aerospace, welding cycle, melting point

1.0 INTRODUCTION

Friction welding is a non-conventional pressure welding process It is considered most viable

alternative to overcome the difficulties faced in conventional joining technique. Mostly used for
joining material with varying physical and mechanical properties. Friction welding is a solid state
joining method (the metal not melt during the process) which produce coalescence of materials under
compressive force when the workpieces rotate or move relative to each other producing heat and
plastically displacing the material from the faying interface . while considering a solid state welding
process, uner some circumstances a molten film may be produce at the interface. However, even then
the final weld should not exhibit evidence of a molten state because of extensive hot working during
the final stage of the process. Filler metal, flux and shielding gas are not required in this process

_______________________
*
Corresponding email: iskandar.kassim@graduate.utm.my (Nor Iskandar Kassim Maniam)
 Mostly used for joining material with varying physical and mechanical properties. This research
mainly focused on Rotary Friction Welding (RFW). In this friction welding process, kinetic energy is
converted into heat energy thereby producing high quality weld and unusually high efficiency
coefficient. Friction Welding is a one of the pressure welding method, the welded connection is
formed without melting the metal, the result from the friction the plastic deformation at joint of the
pieces to be welded with the help of heat. The large generated amount of localised intense heat
generation and deformation results in less energy consumption and highly strong weld.
There is no external application of heat or flux in Friction welding process because this process
does not required any external heat or flux. Minimal or no defects, this is the one of the advantages
of solid-state welding is that it contains minimal or no defects when compared to fusion welding. The
same effects are carried over to friction welding. Other than that, RFW have very fast process that
why the Friction welding is considered one among the fastest welding methods, clocking up to twice
or even 100x faster than normal fusion welds. RFW process also need many surface preparation after
welding, Machined, saw cut or sheared surfaces can be joined using friction welding. However, the
presence of lubricants or oils is not allowed for optimal weld conditions.

2.0 METHODOLOGY
By utilizing a conventional lathes machine, axial pressure was applied manually. The only
parameter this machine provided is rotational speed, in unit of revolution per minute (rpm).
In order to study the welding temperature, an infrared thermometer was used while the experiment
was running. It was used to measure temperature in this experiment because it was safe. It did not
have to be in contact with the copper rods, since the rods were heated to high temperature.
Started with a low rotational speed, which was 1200 rpm, the experiment was carried out. The
speed then was increased; 1700 rpm and 2500 rpm were selected. In these preliminary tests of rotary
friction welding, 2500 rpm was the applicable speed because high temperature can be easily achieved
for the copper rods. Once the welding process had been carried out, the copper rods were put through
the microhardness testing and microstructure testing to study the effects of welding

2.1 Rotary Friction Welding Procedure

Copper rods were bought with dimension of 10mm diameter with 60mm length (Figure3.1). One
copper rod was clamped to the spindle chuck and another one to the stationary chuck (Figure 3.2).
These copper rods were brought together as close as possible by moving the stationary chuck holder
by rotating tailstock wheel (Figure 3.3). Then, the holder was locked.
Rotational speed was adjusted to required speed. Clutch was pushed down to spin the flywheel. It
took a few seconds to rotate at selected speed. Force was applied by rotating tailstock wheel to push
the stationary copper rod towards rotating copper rod. After the copper rods were heated until red
heated, force was keep applied. Clutch was pulled up to stop the spinning of flywheel.
Temperatures of both copper rods were measured on the surfaces by an infrared thermometer
immediately after flywheel stopped. Copper rods were removed from the clamping after they were
cooled.
 Figure 3.1: Copper with diameter 10mm and 60mm

Figure 3.2: copper rod was clamped to the spindle chuck and another one to the stationary chuck

Figure 3.3: Coppeer rods were brought together as close as possible

2.2 EDM Wire Cutting Procedure

Processed copper rods (Figure 3.4) were cut into semi-circle cross section pieces (Figure 3.6) with
length of 10 mm (Figure 3.5) by using an EDM wire cutting machine, Mitsubishi FA10 (Figure
3.12 ).
 Figure 3.4: 60mm copper rod

Figure 3.5: Dimension of 10mm to be cut

Figure 3.6: Desired size of copper piece prior to mounting for both microstructure and microhardness
test.

2.3 Microstructure Test Procedure (preparation)

In order to identify and evaluate the microstructure of material, it is very important to prepare the test
sample carefully and properly. The various steps in sample preparation for microstructural
examination as follows:
1. Mounting the section without damage to the test sample
2. Grinding to achieve a flat sample with a minimum amount of damage to the sample surface
3. Polishing the mounted and ground sample
4. Etching in the proper etchant to reveal the microstructural details
2.4 Mounting

After the copper was cut into the desired size, which was a semi-circle cross- section with 1 cm in
length, it was mounted in a plastic or epoxy material to facilitate handling and the grinding and
polishing steps. The copper piece was put into a cylinder of compression mounting equipment, which
was Buehler Simplimet 1000 Auto Mounting Press. In this study, Buehler Phenolic Powder was used
as the molding compound. One and a half scoop of the powder was poured into the cylinder. With 3
minutes of heating time and 4 minutes of cooling time, the mold was heated and pressurized at
4200psi. Then, the mounted sample was removed from the mold.

2.5 Grinding

Grinding follows mounting to remove the surface damaged and to provide a flat surface. Grinding
generally involves the use of water lubricated abrasive wheels and the use of a series of progressively
finer abrasive grits (Figure 3.25). Grinding papers, Microcut Silicon Carbine Grinding Paper from
P400 to P2400 of grits (Figure 3.23) were used on a grinder, Metaserv 2000 manufactured by Buehler
(Figure 3.24), to get the mounted copper a flat surface that is nearly free of the disturbed or deformed
metal that has been introduced by the mounting process.

2.6 Polishing

The polishing step removes the last thin layer of the deformed metal. It leaves a properly prepared
sample, ready for examination of the unetched characteristics such as inclusion content or any
porosity that may exist. The mounted copper was polished by using a polishing cloth, polishing liquid
which was MetaDi Fluid 40-6032 and polishing paste which was MetaDi Diamond Paste. The
polishing liquid was poured on the polishing cloth. Before polishing started, the polishing paste was
put on the surface of mounted copper. After polishing, the mounted copper was washed with water
followed by ethanol (C2H5OH).
3.0 RESULT AND DISCUSSION

Temperature Specific heat Thermal Coefficient of Density

(o C) (J/kg.K) Conductivity Thermal
(W/m.K) expansion
0 917 162 22.4x10-6 2700
-6
93 978 177 24.6x10
201 1028 192 26.6x10-6
316 1078 207 27.6x10-6
428 1133 223 29.6x10-6
571 1230 253 34.2x10-6
Table 4.1.4- Table for specific heat , thermal conductivity and coefficient of thermal expansion.

SPECIFIC HEAT VS TEMPERATURE

1400

1200

1000

800

600

400

200

0
0 100 200 300 400 500 600

Graph 4.1.4- Graph for specific heat versus temperature

The specific heat is the amount of heat per unit mass required to raise the temperature by one degree
Celsius or Kelvin. The relationship between heat and temperature change is usually expressed in the
form shown below where c is the specific heat. The relationship does not apply if a phase change is
encountered, because the heat added or removed during a phase change does not change the
temperature. From the graph shows that the specific heat for Aluminium Alloy AA6061 in range 0 oC
to 571 oC shows increasing pattern. When the temperature increase the specific heat also increase
from 917 (J/kg.K) to 1230 (J/kg.K).
 THERMAL CONDUCTIVITY VS TEMPERATURE
300

250

200

150

100

50

0
0 100 200 300 400 500 600

Graph 4.1.5- Graph for thermal conductivity versus temperature

Thermal conductivity (often denoted by k, λ, or κ) refers to the intrinsic ability of a material to

transfer or conduct heat. It is one of the three methods of heat transfer, the other two being convection
and radiation. Heat transfer processes can be quantified in terms of appropriate rate equations. The
rate equation in this heat transfer mode is based on Fourier’s law of heat conduction.
Thermal conductivity is achieved by molecular agitation and contact rather than bulk movement of
the solid. Heat flows down a temperature gradient from a high-temperature, high-molecular-energy
region to a lower-temperature, lower-molecular-energy region. This transfer will continue until the
temperature reaches thermal equilibrium. The rate at which heat is transferred is dependent upon the
magnitude of the temperature gradient, and the specific thermal characteristics of the material. From
the graph shows that the Thermal conductivity for Aluminium Alloy AA6061 in range 0 oC to 571 oC
shows increasing pattern. When the temperature increase the specific heat also increase from 162
(W/m.K) to 253 (W/m.K).
 COEFFICIENT OF THERMAL EXPANSION VS TEMPERATURE
40

35

30

25

20

15

10

0
0 100 200 300 400 500 600

Graph 4.1.6- Graph for coefficient of thermal expansion versus temperature

The Thermal expansion coefficient (CTE, a, or a1) is a material parameter that indicates how much a
material expands when heated. Different substances expand to varying degrees. The thermal
expansion of uniform linear objects is proportional to temperature change over narrow temperature
ranges.

ALUMINIUM AA6061 ALLOY JOHNSON-COOK DATA

Material A (MPa) B (MPa) C N M T ref (oC) T melt(oC)

AA6061 324 114 0.002 0.42 1.34 20 652

Specific heat (J/kg.K) Temperature (K)

0.8 10
50 40
240 100
400 300
Table 4.2.4- Table shows the value of specific heat of Brass Alloy
 SPECIFIC HEAT VS TEMPERATURE
450

400

350

300

250

200

150

100

50

0
0 50 100 150 200 250 300 350

Graph 4.2.4- shows the value of specific heat of Brass Alloy versus temperature

Thermal Conductivity ((W/m.K)) Temperature (K)

2 4
40 77
113 273
120 293
Table 4.2.5- Table shows the value of Thermal conductivity of Brass Alloy
 THERMAL CONDUCTIVITY VS TEMPERATURE
140

120

100

80

60

40

20

0
0 50 100 150 200 250 300 350

Graph 4.2.5- shows the value of thermal conductivity of Brass Alloy versus temperature

Thermal expansion Coefficient (10-6/K) Temperature (K)

0.03 10
2 40
10 100
19 300
Table 4.2.6- Table shows the value of Thermal expansion coefficient of Brass Alloy
 THERMAL EXPANSION COEFFICIENT VS TEMPERATURE
20

18

16

14

12

10

0
0 50 100 150 200 250 300 350

Graph 4.2.6- shows the value of Thermal expansion coefficient of Brass Alloy versus temperature

BRASS ALLOY JOHNSON-COOK DATA

Material A (MPa) B (MPa) C N M T ref (oC) T melt(oC)
Brass 112 505 0.009 0.42 1.68 373 1189
 RESULT FROM ABAQUS

ACKNOWLEDGEMENT

I would like to express my deepest gratitude to my supervisor, Dr Uday M Basheer Al Naib for his
supervision, constant support, invaluable help of constructive comment, advice, encouragement and
suggestion throughout the design process and thesis work have continued to the success.
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