Tensile strength and thermal cycle analysis of AA6061 friction weld joints with different diameters and various friction times

Authors

DOI:

https://doi.org/10.15587/1729-4061.2021.227224

Keywords:

Aluminum, Friction Welding, Tensile Strength, Finite Element Analysis, Thermal cycle

Abstract

The paper reports measurement of tensile strength and the thermal cycle of AA6061 aluminum alloy circular bar friction weld with different diameters and various friction times. A continuous drive friction welding (CDFW) of AA6061 was conducted to weld the AA6061 circular bar with different diameters of 30 mm for the rotating part and 15 mm for the stationary part. The CDFW process was carried out with the revolution speed of 1,600 rpm, the initial compressive force of 2.8 kN during the friction stage for various friction times of 10, 12, and 14 seconds, and an upset force of 28 kN for 60 seconds. The flash temperature was measured using a digital infrared thermometer gun. Computer simulation using the finite element method was also done by coupling transient thermal and static structural methods. The flash temperature becomes higher along with increasing friction time based on the digital infrared thermometer gun measurement and finite element analysis. The results of tensile strength testing show that the specimen with a friction time of 12 seconds has the highest tensile strength. Based on the hardness testing result, it is found that the specimen with a friction time of 10 seconds has higher hardness, but it has an incomplete joint flash so that the tensile strength is lower than that of the specimen with a friction time of 12 seconds. Besides, the hardness of the specimen with a friction time of 12 seconds is higher than that of the specimen with a friction time of 14 seconds. The flash size becomes bigger along with the increase of the friction time based on the macrostructure observation on the longitudinal section of the CDFW specimen. It is confirmed by the temperature measurement and finite element analysis that the specimen with a friction time of 12 seconds has heat input to form the CDFW joint that has a maximum tensile strength in the range of this study

Supporting Agencies

  • Ministry of Research and Technology
  • National Research and Innovation Agency
  • Deputy for Strengthening Research and Development

Author Biographies

Yudy Surya Irawan, Brawijaya University

Doctor of Engineering, Assistant Professor

Department of Mechanical Engineering

Moch Agus Choiron, Brawijaya University

Doctor of Engineering, Associate Professor, Head of Laboratory

Design and System Engineering Laboratory

Department of Mechanical Engineering

Wahyono Suprapto, Brawijaya University

Doctorate, Professor

Department of Mechanical 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, 71. doi: https://doi.org/10.1007/978-3-642-54607-5
  4. Rajakumar, S., Muralidharan, C., Balasubramanian, V. (2011). Predicting tensile strength, hardness and corrosion rate of friction stir welded AA6061-T6 aluminium alloy joints. Materials & Design, 32 (5), 2878–2890. doi: https://doi.org/10.1016/j.matdes.2010.12.025
  5. Barnes, T. A., Pashby, I. R. (2000). Joining techniques for aluminium spaceframes used in automobiles: Part I – solid and liquid phase welding. 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. Sathiya, P., Aravindan, S., Noorul Haq, A. (2006). Effect of friction welding parameters on mechanical and metallurgical properties of ferritic stainless steel. The International Journal of Advanced Manufacturing Technology, 31 (11-12), 1076–1082. doi: https://doi.org/10.1007/s00170-005-0285-5
  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., 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. doi: https://doi.org/10.15587/1729-4061.2019.154384
  11. Fukakusa, K. (1997). Real rotational contact plane in friction welding of different diameter materials and dissimilar materials: Fundamental study of friction welding. Welding International, 11 (6), 425–431. doi: https://doi.org/10.1080/09507119709451991
  12. Erol Akata, H., Sahin, M. (2003). An investigation on the effect of dimensional differences in friction welding of AISI 1040 specimens. Industrial Lubrication and Tribology, 55 (5), 223–232. doi: https://doi.org/10.1108/00368790310488887
  13. Can, A., Sahin, M., Kucuk, M. Thermically Evaluation and Modelling of Friction Welding // Strojarstvo, 2009. Vol. 51 (1) P. 5-13. https://hrcak.srce.hr/42501
  14. Sahin, M. (2004). Simulation of friction welding using a developed computer program. Journal of Materials Processing Technology, 153-154, 1011–1018. doi: https://doi.org/10.1016/j.jmatprotec.2004.04.287
  15. Sahin, M. (2001). Investigation of effects of workpiece dimensions and plastic deformation on friction welding method. Edirne.
  16. Służalec, A. (1990). Thermal effects in friction welding. International Journal of Mechanical Sciences, 32 (6), 467–478. doi: https://doi.org/10.1016/0020-7403(90)90153-a
  17. Standard Methods for Mechanical Testing of Welds (7th Edition): (AWS B4.0:2007) (2007). American Welding Society.
  18. Academic Ansys 18.1. Ansys Inc. Available at: https://www.ansys.com
  19. Khan, I. A. (2011). Experimental and numerical investigation on the friction welding process. Jawaharlal Nehru Technological University, 227. Available at: http://hdl.handle.net/10603/3467

Downloads

Published

2021-04-30

How to Cite

Irawan, Y. S., Choiron, M. A., & Suprapto, W. (2021). Tensile strength and thermal cycle analysis of AA6061 friction weld joints with different diameters and various friction times. Eastern-European Journal of Enterprise Technologies, 2(12 (110), 15–21. https://doi.org/10.15587/1729-4061.2021.227224

Issue

Vol. 2 No. 12 (110) (2021): Materials Science

Section

Materials Science

License

Copyright (c) 2021 Yudy Surya Irawan, Moch Agus Choiron, Wahyono Suprapto

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

The consolidation and conditions for the transfer of copyright (identification of authorship) is carried out in the License Agreement. In particular, the authors reserve the right to the authorship of their manuscript and transfer the first publication of this work to the journal under the terms of the Creative Commons CC BY license. At the same time, they have the right to conclude on their own additional agreements concerning the non-exclusive distribution of the work in the form in which it was published by this journal, but provided that the link to the first publication of the article in this journal is preserved.

A license agreement is a document in which the author warrants that he/she owns all copyright for the work (manuscript, article, etc.).
The authors, signing the License Agreement with TECHNOLOGY CENTER PC, have all rights to the further use of their work, provided that they link to our edition in which the work was published.
According to the terms of the License Agreement, the Publisher TECHNOLOGY CENTER PC does not take away your copyrights and receives permission from the authors to use and dissemination of the publication through the world's scientific resources (own electronic resources, scientometric databases, repositories, libraries, etc.).
In the absence of a signed License Agreement or in the absence of this agreement of identifiers allowing to identify the identity of the author, the editors have no right to work with the manuscript.
It is important to remember that there is another type of agreement between authors and publishers – when copyright is transferred from the authors to the publisher. In this case, the authors lose ownership of their work and may not use it in any way.