Tensile strength and fatigue crack growth rate of chamfered and clamped A6061 friction weld joints

Authors

DOI:

https://doi.org/10.15587/1729-4061.2019.154384

Keywords:

Aluminum, Continuous Drive Friction Welding, Tensile Strength, Fatigue Crack Growth Rate, Fracture Surface

Abstract

Friction welding is a solid-state joining technique. It is suitable to be used to join a round bar of aluminum that has problems in joining. This paper reports measurements of the tensile strength and fatigue crack growth rate of a continuous drive friction welding (CDFW) joint of aluminum alloys A6061. The CDFW process was conducted by using the round bar A6061 machined to form a chamfer angle and applying a clamping process before the upset stage. Various chamfer angles of 0, 30, 45, and 60 degrees were machined on the stationary round bar. In order to increase the tensile strength and to reduce the fatigue crack growth rate of the CDFW joint, round clamps were applied on the CDFW joint. CDFW process was conducted with the revolution speed of 1,100 rpm, the initial compression force of 3.9 kN during friction stage for 4 seconds, and an upset force of 28 kN for 60 seconds. The specimens of friction weld joints were machined to shape the specimens of tensile strength testing and fatigue crack growth testing. Fatigue crack growth testing was performed using a cantilever rotary bending machine. The testing results show that using a small chamfer angle together with the round clamp produced a CDFW joint that exhibited higher tensile strength than the joint without chamfer or clamping. The specimen created with a chamfer angle of 30 degrees and the clamping method had the highest tensile strength and the lowest fatigue crack growth rate among the samples studied. This result was caused by smaller heat input as a result of using a small one-sided chamfer together with two stages of plastic deformation from the clamping process and upset process during CDFW. The fatigue crack growth rate is also confirmed by macro and scanning electron microscope imaging of the fracture surfaces. The area of fatigue crack growth of the specimen with high tensile strength is wider than the specimen with lower tensile strength. The striations are also observed more clearly in the fracture surface of the specimen with the highest tensile strength and the lowest fatigue crack growth rate, namely the specimen, which has a chamfer angle of 30 degrees with clamping

Author Biographies

Yudy Surya Irawan, Brawijaya University Jalan. Mayjend Haryono, 167, Malang, Indonesia, 65145

Doctor of Engineering, Assistant Professor

Department of Mechanical Engineering

Fakhri Razaq, Brawijaya University Jalan. Mayjend Haryono, 167, Malang, Indonesia, 65145

Department of Mechanical Engineering

Wahyono Suprapto, Brawijaya University Jalan. Mayjend Haryono, 167, Malang, Indonesia, 65145

Doctorate, Professor

Department of Mechanical Engineering

Bayu Satria Wardana, Brawijaya University Jalan. Mayjend Haryono, 167, Malang, Indonesia, 65145

Master of Engineering, Assistant Professor

Department of Mechanical Engineering

Faculty of Engineering

References

  1. Nicholas, E. D. (2003). Friction Processing Technologies. Welding in the World, 47 (11-12), 2–9. doi: https://doi.org/10.1007/bf03266402
  2. Maalekian, M. (2007). Friction welding – critical assessment of literature. Science and Technology of Welding and Joining, 12 (8), 738–759. doi: https://doi.org/10.1179/174329307x249333
  3. Yilbas, B. S., Sahin, A. Z. (2014). Friction welding. Thermal and metallurgical characteristics. Springer. doi: https://doi.org/10.1007/978-3-642-54607-5
  4. Bauccio, M. (Ed.) (1993). ASM Metals Reference Book. ASM International, 614.
  5. Barnes, T. A., Pashby, I. R. (2000). Joining techniques for aluminium spaceframes used in automobiles. Journal of Materials Processing Technology, 99 (1-3), 62–71. doi: https://doi.org/10.1016/s0924-0136(99)00367-2
  6. Uday, M. B., Ahmad Fauzi, M. N., Zuhailawati, H., Ismail, A. B. (2010). Advances in friction welding process: a review. Science and Technology of Welding and Joining, 15 (7), 534–558. doi: https://doi.org/10.1179/136217110x12785889550064
  7. Sahin, M., Akata, H. E., Gulmez, T. (2007). Characterization of mechanical properties in AISI 1040 parts welded by friction welding. Materials Characterization, 58 (10), 1033–1038. doi: https://doi.org/10.1016/j.matchar.2006.09.008
  8. Lin, C. B., Mu, C. K., Wu, W. W., Hung, H. C. (1999). The effect of joint design and volume fraction on friction welding properties of A360/SiC (p) composites. Welding Journal, 78 (3), 100–108.
  9. Irawan, Y. S., Wirohardjo, M., Ma’arif, M. S. (2012). Tensile Strength of Weld Joint Produced by Spinning Friction Welding of Round Aluminum A6061 with Various Chamfer Angles. Advanced Materials Research, 576, 761–765. doi: https://doi.org/10.4028/www.scientific.net/amr.576.761
  10. Irawan, Y. S., Amirullah, M., Gumilang, G. B. D., Oerbandono, T., Suprapto, W. (2016). Torsion strength of continuous drive friction weld joint of round bar aluminum A6061 affected by single cone geometry of friction area. AIP Conference Proceedings, 1717, 040010. doi: https://doi.org/10.1063/1.4943453
  11. Callister, W. D. (2001). Fundamentals of Materials Science and Engineering. John Wiley & Sons Inc.
  12. Yamamoto, Y., Ochi, H., Sawai, T., Yamaguchi, H., Ogawa, K. (2007). Fatigue Strength of Friction-Welded 6061 Aluminum Alloy Joints. MATERIALS TRANSACTIONS, 48 (11), 2909–2913. doi: https://doi.org/10.2320/matertrans.l-mra2007880
  13. Mercan, S., Aydin, S., Özdemir, N. (2015). Effect of welding parameters on the fatigue properties of dissimilar AISI 2205–AISI 1020 joined by friction welding. International Journal of Fatigue, 81, 78–90. doi: https://doi.org/10.1016/j.ijfatigue.2015.07.023
  14. Zhang, Y., Sakai, T., Osuki, H., Yamamoto, T., Kokubu, A. (2011). Very High Cycle Fatigue Characteristics of Zr-Base Bulk Amorphous Alloy in Rotating Bending. Journal of Solid Mechanics and Materials Engineering, 5 (10), 519–533. doi: https://doi.org/10.1299/jmmp.5.519
  15. Standard Methods for Mechanical Testing of Welds (2007). Miami: American Welding Society, 2007.
  16. Kuhn, H., Medlin, D. (Eds.) (2000). ASM Handbook Volume 8: Mechanical Testing and Evaluation. Ohio: ASM International, 998.
  17. Rafi, H. K., Ram, G. D. J., Phanikumar, G., Rao, K. P. (2010). Microstructure and tensile properties of friction welded aluminum alloy AA7075-T6. Materials & Design (1980-2015), 31 (5), 2375–2380. doi: https://doi.org/10.1016/j.matdes.2009.11.065

Downloads

Published

2019-12-21

How to Cite

Irawan, Y. S., Razaq, F., Suprapto, W., & Wardana, B. S. (2019). Tensile strength and fatigue crack growth rate of chamfered and clamped A6061 friction weld joints. Eastern-European Journal of Enterprise Technologies, 6(12 (102), 31–39. https://doi.org/10.15587/1729-4061.2019.154384

Issue

Section

Materials Science