Research Proposal
Advancement in Friction Stir Welding Tool’s Coating Material
Submitted to: Dr. Zafar Iqbal
By
Bilal Abbas (DMME)
Naima Sadiq (DMME)
Usama Nasir (DMME)
Abstract
This research proposal outlines a comprehensive plan to assess the performance of tungsten
carbide cobalt (WC-Co) tool materials with varying cobalt content (6%, 9%, and 12%) both with
and without a titanium aluminum nitrate (AlTiN) coating in the context of friction stir welding
(FSW). The evaluation will involve two key experimental methods: Vickers hardness testing and
scratch testing to make comparisons and assess material performance.
The research aims to investigate how the cobalt content influences material hardness, with
higher cobalt content resulting in increased hardness. Conversely, it seeks to understand the
impact of the coating on adhesion, where higher cobalt content is expected to decrease
adhesion strength. The rationale for conducting these comparisons lies in the fact that each
material type exhibits distinct hardness and adhesion properties. This is essential in the pursuit
of identifying exceptionally robust materials capable of withstanding rapid temperature
changes and substantial friction in FSW applications.The inclusion of the coating is integral as it
serves to extend the lifespan of the material and can function as a lubricant for the FSW tool.
Strong adhesion between the coating and the material enhances the material's lifespan, making
it a critical factor in this research.
Introduction
FSW is a new type of welding by using heat from friction to fuse two metal together. Initially,
this type of welding is using soft material like aluminum as its base material. Because of this
type of welding look promising, more study and research is made to increase the performance
of FSW for high strength material. Because of that, a new type of material was introduced to
make the FSW tool more durable and last long. One of the materials that are known for this
type of welding is Tungsten Carbide Cobalt (WC-Co). It is a high strength material commonly
used in FSW because it can withstand sudden change in temperature and loading during the
welding process. To increase the strength for the material, Titanium Aluminum Nitrate (TiAlN) is
added to the WC-Co as a coating to act as a lubricant and to strengthen the material.Besides
TiAlN, .Another type of material that is used in FSW is Polycrystalline cubic boron nitride (pcBN)
and one of the high strength materials that are used in FSW. This material is very strong and
can be compared to diamond strength. However, when compared in high temperature, the
hardness of pcBN is exceeding diamond. Because of this characteristic, pcBN is one of the most
preferred material in FSW but the downside with this material is the price is high. On top of
that, the coating is an important aspect to FSW tools in order to keep the material strong,
durable and lifelong.
Objective
To prolong Tool lifespan by making it strong and durable by:
Studying the relation between cobalt content and material hardness.
Investigating the adhesion strength of TiAlN coating on different substrates of cobalt
content (6%, 9% and 12%).
Problem Statement
The tools used in FSW for MMC’s undergo rapid and severe tool wear due to the contact
between the tool and the stronger particle reinforcement.
Methodology
The methodology begins with designing the material, which takes the form of a rectangular
shape measuring 8cm x 1cm x 1cm. This particular shape is selected because the primary focus
of this study is to investigate the hardness and adhesion strength of FSW material. The choice
of this shape simplifies the experimental process. Before proceeding to fabrication, the
dimensions of the material must be determined and finalized.
Once the material's dimensions are established, the material will be purchased from market.
Subsequently, the rectangular material is further processed by cutting it into smaller cube-sized
pieces, each measuring 1cm x 1cm x 1cm. This smaller size is essential for conducting the
scratch test, a critical component of the research.
The next steps involve coating the material with TiAlN from PINSTECH and then conducting
mechanical tests to examine the material's morphology. These tests encompass hardness
assessments and scratch testing.
