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T.C. ALTINBAŞ UNIVERSITY Institute of Graduate Studies Mechanical T.C. ALTINBAŞ UNIVERSITY Institute of Graduate Studies Mechanical Engineering A MODEL FOR THE DISTRIBUTION OF TEMPERATURE ON THE ALUMINUM ALLOY WHEN USING FRICTION WELDING Sewara Mohsin Mahealdeen SHEKHAN Master Thesis Supervisor Asst. Prof. Dr. Hakan KAYGUSUZ Istanbul, (2020) A MODEL FOR THE DISTRIBUTION OF TEMPERATURE ON THE ALUMINUM ALLOY WHEN USING FRICTION WELDING By Sewara Mohsin Mahealdeen SHEKHAN Mechanical Engineering Submitted to the Graduate School of Science and Engineering in partial fulfillment of the requirements for the degree of Master of Science ALTINBAŞ UNIVERSITY 2020 The thesis titled “A MODEL FOR THE DISTRIBUTION OF TEMPERATURE ON THE ALUMINUM ALLOY WHEN USING FRICTION WELDING” prepared and presented by SEWARA MOHSIN was accepted as a Master of Science Thesis in Mechanical Engineering. Asst. Prof. Dr. Hakan KAYGUSUZ Supervisor Thesis Defense Jury Member School of Engineering and Asst. Prof.Dr. Hakan Natural Sciences, KAYGUSUZ AltinbasUniversity __________________ School of Engineering and Asst. Prof.Dr. İbrahim KOÇ Natural Sciences, AltinbasUniversity __________________ Faculty of Engineering and Asst. Prof.Dr. Bengi ÖZUĞUR Natural Sciences Kadir Has UYSAL University __________________ I certify that this thesis satisfies all the requirements as a thesis for the degree of Master of Science. Approval Date of Institute of Graduate studies __/__/__ iii I hereby declare that all information in this document has been obtained and presented in accordance with academic rules and ethical conduct. I also declare that, as required by these rules and conduct, I have fully cited and referenced all material and results that are not original to this work. Sewara Mohsin Mahealdeen SHEKHAN iv DEDICATION I would like to dedicate this work to my first teacher, my mother, my first supporter and role model, my father and my companion throughout the journey. Without you, this dream would never come true and to my brother and my sister who stood with me in order to achieve my dream. v ACKNOWLEDGEMENTS I would like to express my sincere gratitude to all the instructors that have taught me more than just science, especially my supervisor Asst. Prof. Dr. Hakan KAYGUSUZ, for all the time, support and guidance provided to me along the journey to accomplish this work. Thank you all for all the knowledge and advice that made me overcome all the difficulties that I have faces. vi ABSTRACT A MODEL FOR THE DISTRIBUTION OF TEMPERATURE ON THE ALUMINUM ALLOY WHEN USING FRICTION WELDING SHEKHAN, SEWARA MOHSIN MAHEALDEEN M.S. Mechanical Engineering, Altınbaş University, Supervisor: Asst. Prof. Dr. Hakan KAYGUSUZ Date: June / 2020 Pages: 80 Aluminum alloys are characterized by high hardness and high corrosion resistance are used in the construction of various aircraft structures and in spare parts for these aircraft. As a result, these parts need to be bonded between them and from the linking processes by welding method, especially friction stir welding (FSW).In this study, aluminum alloy parts (2024-T6) were used and welded by friction stir welding method. Three types of tool were used (square, triangular and conical) and four rotational speeds were used for the welding tool and three linear speeds for the vehicle that carries the models that it is welded, and temperature distribution has been studied on the surfaces of the models when welding operations are conducted in order to study its distribution on the parts during welding and its effect on tensile strength. Also, a mathematical model was created for welded parts, and these mathematical models were solved using the specified finite elements method through the use of the ANSYS-15.0 program, as well as models for the purpose of testing the tensile strength of all variables. The results of the tests indicate that the distribution of temperatures on the surfaces of the welded models in an acceptable match with the results obtained from the mathematical model, for the mathematical model is of great importance in showing the distribution of temperatures in and around the welding area. The results show that the temperatures generally increase with increasing the rotational speed of the welding tool while decreasing with increasing linear velocity of the welding table. The results also indicate an increase in the flap by increasing the rotational speed of the welding tool and decreasing by increasing the linear velocity of the welding table. The amount of heat traveled from the welding area to the rest of the model increases by increasing the rotational speed of the welding tool and also by increasing the linear velocity of the welding vii table when the welding process is performed. Among the results of tensile strength tests is a variation that the welding efficiency decreases with an increase in the rotational speed of the welding tool slightly. Keywords: Aluminum alloys, friction stir welding, rotational speed, travel speed, tensile strength. viii TABLE OF CONTENTS PAGE DEDICATION.......................................................................................................................... v ACKNOWLEDGEMENTS ................................................................................................... vi ABSTRACT ........................................................................................................................... vii LIST OF FIGURES ................................................................................................................ xi LIST OF TABLES ............................................................................................................... xiii 1 INTRODUCTION............................................................................................................ 1 1.1 FRICTION WELDING ........................................................................................... 1 1.2 TECHNIQUES OF FRICTION PROCESSES ..................................................... 3 1.2.1 Advantages of Conflicting Mixing Process ........................................................... 4 1.2.2 Environmental Benefits ......................................................................................... 4 1.2.3 Power Benefits (Energy Benefits) ......................................................................... 5 1.2.4 Other Advantages................................................................................................... 5 1.2.5 Disadvantages of Conflicting Weldings ................................................................ 5 1.3 LIMITATIONS OF THE CONFLICTING MIXING PROCESS ...................... 5 1.4 THE PROCESS OF STIR FRICTION WELDING ............................................. 6 1.5 FRICTION STIR WELDING ................................................................................ 7 1.5.1 Benefits of Conflicting Stir Welding ..................................................................... 8 1.5.2 The principle of Friction Mixing Welding............................................................. 8 1.5.3 Microstructure of the Welding Zone...................................................................... 9 1.5.4 Conflicting Welding Agents .................................................................................. 9 1.5.5 The Disadvantages of the Process of Welding of Confocal Mixing .................... 10 1.5.6 Specification of the Tool Used in the Process of Mixing the Friction and the Welding of the Mixing of Friction ................................................................................... 11 1.6 ALUMINUM AND ITS ALLOYS ........................................................................ 12 1.6.1 Classification of Aluminum Alloys ..................................................................... 12 1.6.2 Welding of Aluminum and its Alloys .................................................................. 13 1.7 TEMPERATURE DISTRIBUTION & MATERIAL FLOW DURING FRICTION STIR WELDING .......................................................................................... 14 1.7.1 Welding Speed Effect .......................................................................................... 15 ix 1.7.2 The Influence of Tool Rotation Speed ................................................................. 16 1.7.3 Effect of Parameters on the Size of the Stir Zone ................................................ 16 1.8 THE GOAL OF THE RESEARCH ..................................................................... 18 2 LITERATURE REVIEW ............................................................................................. 19 3 EXPERIMENTAL WORK ........................................................................................... 28 3.1 METAL PROPERTY ............................................................................................ 28 3.2 FRICTION MIX WELDING (FSW) ................................................................... 29 3.2.1 Distributing Temperatures When Performing Friction Mix Welding ................. 31 3.3 THE MATHEMATICAL MODEL FOR TEMPERATURE DISTRIBUTION ……………………………………………………………………………………..33 3.4 TENSILE TESTING ............................................................................................. 33 3.4.1 Tensile Test Models ............................................................................................. 34 4 RESULTS AND DISCUSSION .................................................................................... 35 4.1 DISTRIBUTING THE DEGREE OF HEAT TO THE SURFACES OF WELDED PATTERNS ....................................................................................................
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