International Journal of Mechanical Engineering and Technology (IJMET) Volume 10, Issue 01, January 2019, pp. 1751-1761, Article ID: IJMET_10_01_174 Available online at http://iaeme.com/Home/issue/IJMET?Volume=10&Issue=1 ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication Scopus Indexed
BEHAVIOUR OF THREADED CYLINDER TOOL IN THE FRICTION STIR WELDING OF AL-ZRB2 AND AL-SIC COMPOSITE
P. Jayaseelan and T. V. Christy*. Department of Mechanical Engineering, School of Engineering & Technology, Karunya Institute of Technology and Sciences, Karunya Nagar, Coimbatore – 641114, India *Corresponding author
ABSTRACT Friction St ir w elding i s a s olid s tate j oining pr ocess of us ing w ithout any filler material. I n t his w ork, t wo bas e m aterials l ikely A l-MMC’s ar e us ed namely Silicon Carbide and Zirconium di-Boride are used. Hardness Rockwell Value and Tensile Strength Tests are evaluated to the various tool material respect to Al-ZrB2 and Al-SiC. Threaded Cylinder Tool made of the materials likely OHNS, HCHCr, H13 are carried out in the process with D/d Ratio are used. The process is carried out with three different tool materials and two different base material mainly aluminium reinforced Zirconium diboride (Al-ZrB2) and Silicon Carbide (Al-SiC). The Micrograph of each four zones for the tool material and base material is shown. This paper mainly focusing on which the tool material shows a maximum tensile and hardness value for two base materials.
Keywords: Friction Stir Welding; Threaded Cylinder; Tool Material; Al-ZrB2, Al-SiC D/d Ratio. Cite this Article: P. Jayaseelan and T. V. Christy, Behavior of Threaded Cylinder Tool in the Fr iction St ir Wel ding of A l-Zrb2 and A l-Sic C omposite, I nternational J ournal of Mechanical Engineering and Technology, 10(01), 2019, pp.1751–1761 http://iaeme.com/Home/issue/IJMET?Volume=10&Issue=1 1. INTRODUCTION Friction Stir Welding is initially developed by “The Welding Institute” (TWI) in December 1991. Friction Stir Welding is a Solid state joining process that creates a frictional heat between the plates or where the tool i s pl unged. T he poor w elds are caused b y detrimental phases can be avoided in this type of welding. Tool plays a major part in the non-consumable welding process. By t he r otational of t he t ool, pl astic def ormation occur s bet ween t he contact s urfaces. Tool geometry, tool profile, and tool material are plays an important role in completing the successful welded joints. The four main process parameter includes speed of the rotation, traverse speed, plunging depth and tilt angle. The length of the tool is slightly smaller than the thickness of the plates. Especially, Friction stir welding is originally adapted for welding the Aluminium alloys.
http://iaeme.com/Home/journal/IJMET 1751 [email protected] P. Jayaseelan and T. V. Christy
This welding process does not require any filler material. According to the macro view, the four different zones are classified and considered. They are unaffected zone or Base metal (BM), Heat- Affected zone (HAZ), Thermo-mechanically heat affected zone (TMAZ), and stirred zone (SZ) or Nugget Zone (NZ). Basically Zones are divided by its microstructure and temperature variations. Especially, the Weld Zone has higher amount of temperature compared to the Thermo- mechanically affected zone. Then, the thermos-mechanically affected zone has higher temperature t han ov er t he ot her and s o on. E ach zones having t he di fferent microstructure properties and strength. Here, this process is mainly focused on the Aluminium reinforced Silicon Carbide and Zirconium diboride are mainly focused with three different threaded tool material known as H 13, OHNS, HCHCr. D /d ratios and pr ocess parameter are assessed and tabulated. Comparing the strength between the Al-SiC and Al-ZrB2 are shown in the following tables. 2. EXPERIMENTAL PROCEDURE:
2.1. Friction Stir Welding Tool Friction stir welding tool consists of round shoulder and pin was used. Basically pin will have the factor of different profiles such as threaded, tapered, conical etc...So selecting the proper tool for the base material is a play. Proper design and dimensions should be followed then the profile was to be done accordingly. Proper selection of tool will provides a proper weld quality. Rotating shoulder along with the pin is fixed into the CNC machine and operated numerically. Selection of appropriate tool and tool design plays an important role in the FSW process. In this case, we used the Threaded Cylindrical tool as shown in Figure 1.
2.2. Tool Material Used FSW tool plays an important role and selection of tool material achieves proper weld quality and long-durable purpose. For this study we discussed H13, OHNS, and HCHCr for the Al-ZrB2 and Al-SiC. Selecting good material for the tool will have high dur ability t han the other material. Using tool material, should withstand the peak temperature of the welding process, so that the welding process can be done. The FSW process only done, if the tool withstand from thermal properties. Comparing one tool material with other materials should be done, so that we came to know that which material exhibits the high strength. The tool should be designed with all this concern including its material, mechanical and thermal properties. In this case, we using the three various tool profiles are Oil Hardened Normalized Steel (OHNS), High Carbon High Chromium steel ( HCHCr) and H 13 St eel. A ccording t o K Palani, C E lanchezhian, K aranam Avinash, C Karthik, Karra Chaitanya, Karthick Sivanur, K Yugandhar Reddy shows that, the non- consumable FSW tool was designed based on the requirements with the dimensions of shoulder diameter and prolonged pin diameter.
2.3. Choice of Tools In this case, we us ed t hree di fferent non- consumables t ool m aterials was us ed t o f ind out the amount of deformation and at the end of the process, proper weld should be obtained only if the grains are uniformly distributed. Here the three different tool materials used are i) High Speed Steel (H13 steel), ii) Oil Hardened Normalized Steel (OHNS), iii) High Carbon High Chromium steel (HCHCr) are tool materials carried out in the FSW process to find out which tool material and profile possess in such a way of equally distributed grains in the microstructural characterization. The tool is designed in such a way that followed by the shoulder diameter to the prolonged pin diameter in terms of D/d ratio.The following Table 1.shows the tool profile, tool material and corresponding D/d ratio are shown as below.
http://iaeme.com/Home/journal/IJMET 1752 [email protected]
Behavior of Threaded Cylinder Tool in the Friction Stir Welding of Al-Zrb2 and Al-Sic Composite
Table 1. Shows Tool Profile, Tool Material, D/d Ratio Tool Tool Profile Tool Material D/d ratio no. 1 Threaded Cylinder H13 2 2 Threaded Cylinder OHNS 3 3 Threaded Cylinder HCHCr 4
2.4. Process In this pr ocess, the m aterial used was A luminium metal matrix composites (MMC’s) Al-10% ZrB2 and SiC with the dimension of the plates are 100 mm x 50 mm x 6 mm manufactured by in- situ stir casting process was employed as weldments for the Friction stir welding. The enforcements such like Aluminium reinforced with Zirconium diboride and Silicon Carbide is known for improved wear resistance and tensile strength but reduced corrosion resistance. As we know that, FSW basically a welding technique for welding the Aluminium and MMC’s due to withstand the high melting point, hardness and stability. The microstructure of Al-ZrB2 and Al- SiC is shown in Figure 3 and 2. According to K Palani, C Elanchezhian, K H V Saiprakash, K Sreekanth, Dayanand, Keshav Kumar, Deepak Kumar that the better microstructural results were observed in friction stir processing joints relate to the friction stir welded joints and the addition of nanoparticles improved the surface and joint properties and also they discussed Aluminium alloys in addition to nanoparticle Al2O3 and SiC showed the sound defect free joints compared to other joints. Proper selection of tool material is necessary so that we obtain a good quality of welds.
Figure 1 – Threaded Cylinder 1 – H13, 2 – OHNS, 3 – HCHCr
Figure 2 – Optical Micrograph of Al-ZrB2
http://iaeme.com/Home/journal/IJMET 1753 [email protected]
P. Jayaseelan and T. V. Christy
2.5. Parameter Used Welding parameters used in this case are shown in table 3. Parameter includes downforce or axial load, rotational speed, tilt angle and traverse speed. Here 1000 rpm, 25 mm/min, 3.8-4.3 kN were applied and used in this process. By the parameters used, H13 showed the superior results when compared to the other two tools materials. In general, parameters plays an important role in defect free joint, as the nominal parameters should use for obtain the good quality weld.
Figure 3 – Optical Micrograph of Al-SiC
Table 2 Shows Tool Configuration
Factor 1 Factor 2 Factor 3 Response 1 Run A:Profile B:Material C:D/d Selected Tool 1 3 2 1 1 2 2 2 2 2 3 1 2 3 3
Figure 4 – FSW Welded Al-ZrB2 and Al-SiC with corresponding tool Used 3. EXPERIMENTAL PROCEDURE:
3.1. Mechanical Characterization Tests like Tensile strength and Hardness test are conducted to the friction stir welded specimens are Al-SiC, Al-ZrB 2 are prepared as per ASTM E08 standard. Tensile tests are conducted as per the standard and concludes the results in MPa for both the specimen. Comparing the results with other tool materials H13 has a maximum strength than the OHNS and HCHCr. The D/d ratios are tabulated in the table 1. Table 4 and 5 represents the Tensile Strength for the both Specimens Al- SiC and Al-ZrB2 are shown. Comparing the results, the higher strength obtained to the H13 tool material as 150 and 117 MPa for the Al-SiC and Al-ZrB2. Thus, H13 proven that possess higher strength to Al-SiC and Al-ZrB2 than the other two tool materials. Rockwell Hardness test was
http://iaeme.com/Home/journal/IJMET 1754 [email protected]
Behavior of Threaded Cylinder Tool in the Friction Stir Welding of Al-Zrb2 and Al-Sic Composite
evaluated for the specimens known to be Al-SiC and Al-ZrB 2 respectively are conducted. The welded specimens with three different tool materials are tabulated in the table 5. Comparing with other tool material, H13 possess higher hardness value in terms with both the Al-SiC and Al- ZrB2. Rockwell Hardness value of tool material H13 for Al-SiC is 41 and Al-ZrB2 is 40. Other tool materials possess lower hardness value than the H13. Hence, H13 provides higher hardness value for both the base materials.
Table 3 shows Parameters used in the process
Traverse Speed Tool Rotation (in rpm) Axial load Applied (kN) Sl.No (mm/min) Run 1000 25 3.8 – 4.3
Table 4 shows Tensile Strength of Al – ZrB2 and Al-SiC in MPa Sl.No Tool Profile Tool Material Al-SiC Al-ZrB2 1 Threaded Cylinder H13 150 117 2 Threaded Cylinder OHNS 121 80 3 Threaded Cylinder HCHCr 93 69
Table 5 shows Rockwell Hardness Value (HRA) of Al-ZrB2 and Al-SiC
Sl.No Tool Profile Tool Material Al-SiC Al-ZrB2 1 Threaded Cylinder H13 41 40 2 Threaded Cylinder OHNS 31 35 3 Threaded Cylinder HCHCr 24 34
3.2. Metallurgical Characterization According to Mohd Atif Wahid, Arshad Noor Siddiquee, Zahid A. Kahn, Nidhi showed that Due to hi gh heat exper ienced dur ing t he FSW, t he degr ee of def ormation of thermal s oftening of materials gets increased leading to high level of plastic deformation as compared to UFSW and CFSW. The Micrographs for the four different welded zone are shown in the figure 6 and 7 for Al-SiC and Al-ZrB2 is shown. Here, four zones such as Parent Metal (PM) Zone, Heat Affected zone ( HAZ), t hermos-mechanically af fected zone ( TMAZ) and weld nugget zone ( WNZ) are denoted for each micrographs termed as two different base material (Al-SiC and Al-ZrB2 ). The term weld nugget zone is known to be welded zone which the temperature is more in this area. The strength should be more than that of base material in the nugget zone and that fulfils the condition of the Al-SiC and Al-ZrB2 only if the H13 tools was used. The microstructure of the welded zone using H13 tool is shown in figure 6 and 7. In this case, parent metal and weld nugget zone are satisfies the condition rather than OHNS and HCHCr. The run in each cases used are 1000 rpm, 25 mm/min were used in both the cases. The presence of finer grain particles were obtained without any defects only in the case of H13 tool material. The non-uniform distribution of grain particles and insufficient breaking of the reinforcements are obtained by using other tool materials. Using the Al-SiC with H13 shows a superior prior results in the microstructure changes as compared to Al-ZrB2. Evaluated results are shown and when comparing with H13 tool shows a superior tensile strength and hardness value when compared to other two tools. As we can see that the defect free joint is obtained using the H13 threaded cylindrical tool, shows a superior tensile strength, and Hardness value in both the cases. The macrostructure and values are compared as shown in figure 5.
http://iaeme.com/Home/journal/IJMET 1755 [email protected]
P. Jayaseelan and T. V. Christy
Figure 5 – Macrostructure of Welded Joints
Figure 6 - Micrographs of Al-ZrB2 composites welded using tool no.1 - H13, threaded cylinder pin
http://iaeme.com/Home/journal/IJMET 1756 [email protected]
Behavior of Threaded Cylinder Tool in the Friction Stir Welding of Al-Zrb2 and Al-Sic Composite
Figure 7 – Micrographs of Al-SiC composites welded using tool no.1 - H13, threaded cylinder pin
Figure – 8 Micrographs of Al-ZrB2 composites welded using tool no 2 – OHNS, threaded cylinder pin
http://iaeme.com/Home/journal/IJMET 1757 [email protected]
P. Jayaseelan and T. V. Christy
Figure – 9 Micrographs of Al-SiC composites welded using tool no 2 – OHNS, threaded cylinder pin
Figure 10 Micrographs of Al-ZrB2 composites welded using tool no 3 – HCHCr, threaded cylinder pin
http://iaeme.com/Home/journal/IJMET 1758 [email protected]
Behavior of Threaded Cylinder Tool in the Friction Stir Welding of Al-Zrb2 and Al-Sic Composite
Figure 11 Micrographs of Al-SiC composites welded using tool no 3 – HCHCr, threaded cylinder pin
4. CONCLUSION After completing of the welding process with three different tool materials and two different base materials comparing with the values in terms of strength and hardness, the following results are concluded. Friction s tir w elded us ing H 13 T hreaded c ylindrical t ool pos sess hi gher U ltimate tensile strength (UTS) of 150 and 117 MPa comparing with other two tools namely, OHNS threaded cylinder and HCHCr threaded cylinder for in both cases of Al-SiC and Al-ZrB2 respectively When examined with Rockwell Hardness test (HRA) welded with H13 Threaded cylindrical tool which possess higher value of 41 and 40 comparatively with other two tools for both cases in Al-SiC and Al-ZrB2 respectively.
Studying the Micrographs of Al-SiC and Al-ZrB2 showing that welded using threaded H13 tool cylinder pin showing quality welded joints. For both the Al-SiC and Al-ZrB2 welded with H13 threaded cylinder showing the maximum results in the case of tensile strength, hardness test and also micrographs. REFERENCES
[1] I K Chernykh, E V Vasil’ev, E N Mtuzko, and E V Krivonos 2018 Upgrading weld quality of a friction stir welded aluminium alloys AMG6 (Journal of physics) [2] Suresh C hand, Vineetha S, Ma dhusudhan D, S ai Krishna C H, Kusuma Devi G , Bhawani, Hemarao K, G anesh Naidu G 2 018 E ffect of FSW We lding S peed on microstructure and microhardness of Al-0.84Mg-0.69Si-0.76Fe alloy at moderate rotational tool velocity (Material Science and Engineering) [3] R Marstatt, M Krutzlinger, J Luderschmid, G Constanzi, J F J Mueller, F Hairler and M F Zaeh 2018 Intermetallic layers in temperature controlled Friction Stir Welding of Dissimilar Al-Cu Joints (Material Science and Engineering)
http://iaeme.com/Home/journal/IJMET 1759 [email protected]
P. Jayaseelan and T. V. Christy
[4] M Mi lcic, T V uherer, I R adisavljevic, D Mi lcic, J K ramberger a nd B A ndjelkovic 2018 Mechanical behaviour of Al2024 alloy welded by friction stir welding (Material Science and Engineering) [5] Atul Chauhan, Tarun Soota and S K Rajput 2018 Investigation of Effects of Process Parameters on properties of Friction stir welded Joints (Material Science and Engineering) [6] D Vijayan, PAbhishek 2018 Multi Objective Process Parameters Optimization of Friction Stir Welding using NSGA – II (Materials and Manufacturing Engineering) [7] M A Constantin, A Bosneag, E Nitu, M Iordache 2018 Orientation of Process Parameters values of TIG assisted FSW of Copper to Obtain improves mechanical properties (Material Science and Engineering) [8] P Raja, S Bojanampati, R Karthikeyan, R Ganithi 2018 Effect of rotation speed and welding speed on friction stir welding of AA1100 Aluminium alloy (Material Science and Engineering) [9] M Uthayakumar, V Balasubramaniam, Ahmad Majdi, Abdul Rani, Branislav Hadzima 2018 Effects o f W elding o n t he f atigue b ehaviour o f C ommercial A luminium A A-1100 Joints (Material Science and Engineering) [10] A B osneag, M A C onstantin, E N itu, M L ordache 2 018 F riction S tir W elding o f three dissimilar aluminium alloy: AA2024, AA6061 and AA7075 (Material Science and Engineering) [11] K P alani, C E lanchezhian, K H V S aiprakash, K S reekanth, D ayanand, K eshav Kumar, Deepak Kumar 2018 Effect of Welding Parameters on mechanical properties of dissimilar Friction Stir Processed AA8011 and AA5083-H321 Aluminium alloys (Materials and Manufacturing Engineering) [12] Umasankar D as, R atnakar Das, V ijay T oppo 2 018 We ar B ehaviour s tudy o f F riction Stir Welded Dissimilar metals: AA6101-T6 and AA6351-T6 Aluminium Alloys (Material Science and Engineering) [13] A Bachmann, M Krutzlinger and M F Zaeh 2018 Influence of the Welding temperature and the welding speed on the mechanical properties of friction stir welds in EN AW-2219-T87 (Material Science and Engineering) [14] Subramanya R P rabu, Arun S hettigar, Me rvin H erbert, a nd S hrikantha R ao 2 018 Multi Response O ptimization o f f riction s tir w elding P rocess v ariables u sing T OPSIS approach (Material Science and Engineering) [15] Hua Zhang, Changyu Zhao, Bing Cui, Xuemei Yan, Chengliang Dou, Tongge Shao and Rui Pan 2 018 The Corrosion b ehavious of c old s pray c oating on 2 219 a luminium alloy joints prepared by friction stir welding (Journal of Physics) [16] K Palani, C Elanchezhian Karanam Avinash, C Karthik, Karra Chaitanya, Karthick Sivanur, K Yugandhar Reddy 2 018 Influence of Friction Stir Processing P arameters on Tensile properties and Microstructure of Dissimilar AA8011-H24 and AA6061-T6 aluminium alloy joints in Nugget zone (Material Science and Engineering) [17] Noor Zatman Khan, Mohammed Ubaid, Arshad Noor Siddiquee, Zahid A. Khan, Abdulrahman Al-Ahmari, Xizhang Chen, Mustafa Haider Abidi 2018 Microstructural features of f riction s tir welded d issimilar aluminium alloys AA2219-AA7475 (Material Science and Engineering) [18] Nidhi Sharma, Zahid A.Khan, Arshad Noor, Siddiquee, Suha K. Shihab, Mohd Atif Wahid 2018 Effect of Process parameters on microstructure and electrical conductivity during FSW of Al-6101 and Pure Copper (Material Science and Engineering) [19] A Daneji, M Ali, S Pervaiz 2018 Influence of Tool Geometry and Processing Parameters on Welding defect and mechanical properties for friction stir welding of 6061 Aluminium Alloy (Material Science and Engineering)
http://iaeme.com/Home/journal/IJMET 1760 [email protected]
Behavior of Threaded Cylinder Tool in the Friction Stir Welding of Al-Zrb2 and Al-Sic Composite
[20] Gyander G hangas, S andeep Singhal 2018 E ffect o f t ool p in p rofile a nd dimensions on mechanical properties and microstructure of friction stir welded armor alloy (Material Science and Engineering) [21] Mohd Atif Wahid, Arshad Noor Siddiquee, Zahid A. Kahn, Nidhi Sharma 2018 Analysis of Cooling media effects on microstructure and mechanical properties during FSW/UFSW of AA6082-T6 (Material Science and Engineering) [22] Ashish Jacob, Sachin Maheshwari, Arshad Noor Siddiquee and Namrata gangil 2018 Improvements in strength and microstructural behavious of friction stir welded 7475 aluminium alloy using in-process cooling (Material Science and Engineering) [23] V R Barath, R Vaira Vignesh, R Padmanaban 2018 Analysing the strength of friction stir welded dissimilar aluminium alloys using Sugeno Fuzzy model (Material Science and Engineering) [24] D.Raghavendra and S.Sravya, Influence of Process Parameters on Mechanical Properties of Friction Stir Welding of Aa 6061-T6 Alloy, International Journal of Mechanical Engineering and Technology 8(11), 2017, pp. 528–534.
http://iaeme.com/Home/journal/IJMET 1761 [email protected]