Design, Development and Performance Analysis of a Friction Welding for Dissimilar Metals

• Published in: Lecture notes in engineering and computer science Vol. 2235/2236; p. 540
• Main Authors: Kilic, Murat, Murali, R V, Mutlag, S F
• Format: Journal Article
• Language: English
• Published: Hong Kong International Association of Engineers 04.07.2018
• Subjects: Aluminum; Copper; Dissimilar material joining; Dissimilar materials; Dissimilar metals; Friction welding; Low carbon steels; Metallurgy; Metals; Property values; Rods; Solid state; Stainless steel; Stainless steels
• ISSN: 2078-0958; 2078-0966

Advancements in welding have been rapid in recent times and joining two similar and dissimilar metals in solid state of metal is on high demand as revealed from the literature studies. Friction Welding (FW) is one such advanced technique of uniting two parent metals at solid state. The fundamental advantage of the FW is that is more efficient in joining the dissimilar materials as this method provides outstanding weld seam with good mechanical and metallurgical properties in comparison to other welding methods. Unavailability of a FW set up in CCE is also another source of inspiration that is addressed through this project work. Selection of work holding parts, prime moving devices and design of a suitable electronic controller pose a greater challenge in making the FW set up. There is no reservation on the geometry of work pieces (such as plates, pipes and rods) that can be welded. However, in this work, round cylindrical metallic solid rods of diameter ranging from 10 mm to 20 mm are welded using FW set up. Similar and dissimilar base metals (mild steel to mild steel, stainless steel to stainless steel, copper to aluminium and copper to bronze) are welded with this process. The FW on stainless steel and mild steel rods was achieved at a rotational speed of in the range from 2100 rpm to 2400 rpm while the temperature of heat generated ranges between 950oC to 1000oC. Finally, welded pieces are subject to tensile testing on UTM in order to compare the results obtained through FW with that of conventional or other advanced welding methods so as to confirm the usefulness of this set up. The testing results show good agreement in most of the cases and in some cases, welding conditions to be improved to achieve the full efficiency and comparable mechanical property values.