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Reddy, Ravinder
- Finite Element Analysis of Friction Welding Process for Al 6061 and SS 304
Authors
1 JNTUH, Mech. Dept, CBIT, Hyd, IN
2 Mech. Dept, CBIT, Hyd, IN
3 JNTUH College of Engg., IN
4 Concurrent Analysis Pvt. Ltd., IN
Source
Manufacturing Technology Today, Vol 9, No 3 (2010), Pagination: 20-24Abstract
The welding of Al 6061 and SS 304 is susceptible to intermetallic layer formation. The interface properties are degraded as intermetallic thickness increases and the formation of intermetallic compounds strongly depends on local temperature attained during the welding process. The formation of intermetallic layer is responsible for brittle failure of components. In the present study a thermo mechanical model was developed to predict temperature distribution and stress during friction welding process of Al 6061 and SS 304. Temperature dependent material properties are taken into account for analysis. The FE analysis results are compared with experimental results.Keywords
Finite Element Analysis, Friction Welding.
- Experimental Investigations on Friction Welding of AL 6061 and SS 304
Authors
1 JNTUH
2 CBIT
3 JNTUH College of Engineering
4 Friction Welding
Source
Indian Welding Journal, Vol 43, No 2 (2010), Pagination: 25-31Abstract
The friction welding of dissimilar materials is more complicated than welding similar materials due to differences in the physical, thermal, chemical and mechanical properties of base materials. The welding of Al 6061 and SS 304 is susceptible to intermetallic layer formation. The interface properties are degraded due to formation of intermetallic layer at the weld interface. The formation of intermetallic compounds strongly depends on local temperature attained during the welding process. These intermetallic compounds are responsible for brittle failure of the components. In the present study experimental investigations are done on influence of joint geometry on the interface properties of Al 6061 and SS 304 friction welded parts. A new joint geometry is designed for friction welding to enhance the quality of weld joint. The shape of new joint geometry removes the oxides and other unwanted impurities from the joint interface due to formation of burrs during friction phase of welding process.
The advantages of the new joint geometry, when compared to regular joint geometry, are many, which include a) reduction in material consumption, b) reduction is energy consumption, c) use of machine with lower capacity, d) reduction in the formation of intermetallics, e) reduction in the size of the heat affected zone (HAZ) and f) improved mechanical strength.