Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-5, 2017 ISSN: 2454-1362, http://www.onlinejournal.in

Friction Stir On Dissimilar Metals Aluminum Alloy to CuZn34 Brass

1 K.Dayanand, & 2A.Joshi Gowri Shankar Asst. Professor, Mechanical Engineering, Swamy Vivakanadha Institute of Technology

Abstract: In friction stir welding (FSW) a automated. It is also a cleaner and more efficient cylindrical, shouldered tool with a profiled probe is process compared to conventional techniques. rotated and slowly plunged into the joint line between two pieces butted together. The parts have to be clamped onto a backing bar in a manner that prevents the abutting joint faces from being forces apart. Frictional heat is generated between the wear resistant welding tool and the material of the work pieces This causes the latter to soften without reaching the melting point and allows traversing of the tool along with weld line. In this research, lap joining of aluminum alloy and BrassZn34 brass was produced by friction-stir welding during which the aluminum alloy sheet was placed on the BrassZn34. Optical microscopy, scanning electron microscopy (SEM), X-ray diffraction analysis, and energy- dispersive X-ray spectroscopy (EDS) analysis were used to probe the microstructures and chemical compositions. In addition, the mechanical properties Fig.1. Schematic diagram of the of each sample are characterized using both shear and hardness tests. The optimum parameters resulted Friction Stir Welding process [2] in no visible welding cracks and defects. A dark area in the Al/BrassZn34 interface contained inter It was realized in the development of the FSW metallic compound. In addition, the results show that process that the tool design is critical in producing using high rotational speeds or low traverse speeds sound welds [3]. A basic and conventional design causes the growth of the interfacial inter metallic for a FSW tool is shown in Fig. 2 which consists of area. a threaded pin and a concave shoulder. FSW tools follow the same basic trends in terms of their 1. Introduction shapes and geometries. They are generally comprised of three generic features including a In late 1991 a very novel and potentially world shoulder, a probe also known as a pin and external beating welding method was conceived at TW1. The features on the probe. process was duly named friction stir welding (FSW), and TWI filed for world-wide patent protection in December of that year. TWI (The Welding Institute) is a world famous institute in the UK that specializes in materials joining technology. Consistent with the more conventional methods of friction welding, which have been practiced since the early 1950s, the weld is made in the solid phase, that is, no melting is involved. Compared to conventional friction welding. FSW uses a rotating tool to generate the Fig.2. A Schematic View of FSW Tool necessary heat for the process. Since its invention, (Timothy) the process has received world- wide attention and today two Scandinavian companies are using the FSW joints usually consist of different regions as technology in production, partiBrasslarly for joining illustrated in Fig. 3 following the terminologies used aluminum alloys. Also, FSW is a process that can be by Thread gill [5] which include; the unaffected

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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-5, 2017 ISSN: 2454-1362, http://www.onlinejournal.in material or parent metal, the Heat-Affected Zone is determined based on the material being Brasst. (HAZ), the Thermo Excessive spindle speed will cause premature tool wear, breakages, and can cause tool chatter, all of 2.WORKING PRINCIPLE which can lead to potentially dangerous conditions. In friction stir welding (FSW) a cylindrical, Using the correct spindle speed for the material and shouldered tool with a profiled probe is rotated and tools will greatly affect tool life and the quality the slowly plunged into the joint line between two pieces surface finish. The speed at any point on the butted together. The parts have to be clamped onto a periphery (outside edge) of a Brasstter must always backing bar in a manner that prevents the abutting be equal to the ideal speed for the material for it to joint faces from being forces apart. Frictional heat is work at its optimum performance. The spindle generated between the wear resistant welding tool speeds may be calBrasslated for all machining and the material of the work pieces Thiscauses the operations once the welding speed is known. The latter to soften without reaching the melting point best speed depends on the following conditions. and allows traversing of the tool along with weld 1. Weld strength and quality of the weldment line. The maximum temperature reached is of the required- Higher quality of weld and strength can be order of 0.8 of the melting temperature of the obtained at high speed operations. material. The plasticized material is transferred from 2. Material to be welded – Hard material required the leading edge of the tool to the trailing edge of the high speed operation. tool probe and is forged by the intimate contact of 3. Size of weld . Large welds require low speed the tool shoulder and the pin profile. It leaves a solid operation. phase bond between the two pieces. The process can 4. Thickness of the work piece to be welded. be regarded as a solid phase keyhole welding 4. Feed Rate technique since a hole to accommodate the probe is Feed rate is the velocity at which the generated, then filled during the welding sequence. Brasstter is fed, that is, advanced against the work (a) The process uses a rotating non-consumable pieced. It is expressed in units of distance per weld tool that plunges into the base material and revolution for turning and boring (typically inches moves forward. Friction heat caused by the rotating per revolution (ipr) or millimeters per revolution). It pin creates a plasticized tubular shaft around the pin. can be expressed thus for milling also, but it is often Pressure provided by the weld tool forces the express in units of distance per time for milling plasticized material to the back of the pin, cooling (typically inches per minute (ipm) or millimeters per and consolidation. Al alloy is diffiBrasslt to weld by minute). traditional methods, due to high thermal 5. Depth of Penetration conductivity, resulting in defects like porosity, cracks Depth of penetration depends upon the etc. Hence FSW is being increasingly used. The thickness of the material to be welded. It is expressed process is especially well suited to butt and lap joint in units of millimeters (mm). in aluminum since aluminum is diffiBrasslt to weld by are process, but is very simple to weld by FSW. MATERIAL SUITABILITY TWI (The Welding Institute) has 3.VARIABLES IN FRICTION STIR WELDING concentrated most of its efforts to The use of Friction FSW involves complex material movement Stir Welding (FSW) continues to grow. It is now a and plastic deformation. Welding parameters, tool mature process for joining and is seeing geometry, and joint design exert significant effect on repaid progress in many other engineering alloys. the material flow pattern and temperature Numerous organizations have benefitted from the distribution, there by influencing the micro economic advantages of the FSW process, and this structural evolution of material. In this section, a few symposium will provide the latest information from major factors affecting FSW/FSP process, such as industrial and academic experts from around the tool geometry, welding parameters, joint design are world in this and related technologies optimizing the addressed. The strength of Friction stir welding process for the joining of aluminium and its alloys. depends on the following three process parameters. Subsequent studies have shown the cast to cast and They are cast to extruded (wrought) combinations in similar 1. Spindle speed and dissimilar aluminium alloys are equally possible. 2. Feed rate The following aluminium alloys could be 3. Depth of penetration successfully welded to yield reproducible high integrity welds within defined parametric to clearances: Spindle Speed  2000 series aluminium (A1-Brass) The spindle speed is the rotational frequency of the spindle of the machine, measured in  3000 series aluminium (A1-Mn) revolutions per minute (RPM). The preferred speed

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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-5, 2017 ISSN: 2454-1362, http://www.onlinejournal.in

 4000 series aluminium (A1-Si) 10. MECHANICAL CHARACTERIZATION

 5000 series aluminium (A1-Mg) The knowledge of the mechanical properties of the  6000 series aluminium (A1-Mg-Si) dissimilar friction stir welds between aluminium and  7000 series aluminium (A1-Zn) brass is of importance to enhance their use in the  8000 series aluminium (A1-Li) industries. Research have found that the maximum Ultimate 6. OTHER MATERIALS TensileStrength achieved in FSwelds of aluminium The technology of friction stir welding has and brass was about 296 MPa and it was obtained been extended to other materials also, on which when the tool rotational speed is 950 rpm, and the researches are going on. Some of them are as travel speed is 150 mm/min [13]. Akinlabi [36] also follows- measured the tensile test using different welding  Brass and its alloys parameters, the results showed that the welds  Lead produced had Weld joint efficiencies of between 73  Titanium and its alloys and 86%, and can be acceptable for design purposes.  and its alloys Galvao et al [34] stated that the welding condition, specifically the rotational speeds and the traverse  Zinc speeds that results in obtaining welds with good  Plastics surface appearance do not lead to the production of  Mild steel sound dissimilar welds. Furthermore, Esmaeili et al [32] observed that the Companies practicing and developing FSW mechanical behaviour of joints is influenced as the are spending a lot of money on improving its use for rotational speed increases. They reported that the plastics. It has been demonstrated that FSW is a tensile strength of the weld produced increases due to much more efficient and cleaner process than the formation of a narrow interfacial intermetallic conventional adhesive bonding in plastics. But it is layer and a lamellar composite structure within the yet to be made cost and material effective. Ceramics stir zone. Then, the tensile strength decreases due to is another filed where FSW could be very useful in the disappearance of composite structure and the future. formation of defects in the stir zone [32]. The

thickness of the interfacial intermetallic compound 7. ADVANTAGES OF FRICTION STIR formation increases with an increase in the rotational WELDING speed which results in the reduction of the tensile  The process is environment friendly strength of the welds produced [32]. since no fumes or spatter is generated Li et al [31] observed that the micro hardness and no shielding gas is required. values measured are higher at the brass side of the  FSW is energy efficient nugget zone than that at the aluminium side, this is  A non consumable tool is used. expected as the UTS of Brass is higher than that of  FSW produces desirable the aluminium. Additionally, they found that the microstructures in the weld and heat- hardness at the bottom of the nugget is generally affected zones. higher than other regions due to the stirring action of 8. APPLICATIONS OF FSW the tool pin leading to recrystallized grains. The UTS a) Ship building and marine industries. and the percentage elongation of the dissimilar joints b) Aerospace industry were 152 MPa and 6.3%, respectively, and the c) Railway industry dissimilar joints failed in a ductile-brittle mixed d) Land transportation fracture mode [31]. e) Construction industry Akinlabi and Akinlabi [30] observed that there is f) Electrical industry an increase in the microhardness values at the joint g) Other industry sectors interfaces of the welds resulting from strain hardening due to the stirring of the tool pin and the 9.LIMITATIONS OF FRICTION STIR shoulder previously ocBrasspied by these regions WELDING during the welding process while the high peaks are  Welding speeds are moderately slower due to the presence of intermetallics compounds  Work pieces must be rigidly clamped resulting at the joints interface.  Backing bar required However, Xue et al [29] demonstrated that the  Keyhole at the end of each weld FSW lap Al/Brass joints failed in the HAZ of the Al  Requirement of different length pin tools side, and the tensile shear load reached up to 2680 N when when the Al plate was fixed on the advancing side.  Welding materials of varying thickness

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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-5, 2017 ISSN: 2454-1362, http://www.onlinejournal.in

The hardness increased clearly in the layered compounds. The average tensile properties of the structure due to the strengthening effect of the friction stir weld joints of Brass/Al varied from 138.7 Al/Brass intermetallics, which were mainly MPa to 135.5 MPa [26]. composed of Al4Brass9 phases [29]. Shukla and Shah [27] found that the maximum The study conducted by Xue et al [14] found that tensile strength of Al/Brass joint was low (62.2 MPa) the mainly due to the presence of intermetallic large tensile specimen of the Al–Brass joint compounds. The increase in the rotational speed fractured at the HAZ of the Al side with a 13% resulted in lower tensile strength mostly due to the elongation. The Ultimate Tensile Strength (UTS) and increase in the amount of the intermetallic the yield strength were ~90% and ~80% of the Al compounds formed at the Al/Brass interface [27]. base material respectively, and slightly lower than Furthermore, in the stir zone, the hardness was those of the Al base material due to annealing slightly higher than the base metals also due to the softening during the FSW process while the mini- formation of hard and brittle intermetallic specimen fractured at the particles-rich zone (PRZ), compounds of BrassAl2, BrassAl and Brass9Al4 in and the UTS was about 210 MPa which was much the stir zone [27]. Saeid et al [20] achieved maximum higher than the Al BM [14]. tensile shear strength of lap joint between Bisadi et al [15] found that maximum hardness aluminum and brass through FSW at welding speed values were measured at the brass side of the joint at of 95 mm/min. Due to the formation of high amount the weld SZ because of its fine grain size. In of microcracks in the dark area at welding speeds of addition, although the grain size reductions, the 30 and 60 mm/min, the tolerable tensile shear was hardness values of the joint aluminum side SZ were lower than that of 95 mm/min. While at higher considerably lower than the aluminum base material welding speeds of 118 and 190 mm/min, the cavity defects were produced and again tensile shear which could be due to the production of micro voids strength decreased compared to 95 at this area. mm/min [20]. Moreover, intermetallic compounds were detected In addition to the tensile testing and mostly at the brittle fracture areas and all the ultimate microhardness, Akinlabi et al [20] measured the tensile stresses decreased by increasing the process electrical resistivity of the welds. The results ranged temperature [15]. Poor tensile properties were between 0.087 and 0.1 µΩ. It was observed that the achieved at the very large pin offsets and/or low welds with the highest electrical resistivity of 0,101 rotation rates by Xue et al [16] which they suggested µΩ were measured in those welds produced with could be due to the insufficient reaction between the high heat inputs. Brass bulk / pieces and the Al matrix. Furthermore, In most of the above reviewed research outputs, good tensile properties were achieved in the FSW friction stir welding could be in the future the most Al Brass joints produced at higher rotation rates and – used joining technique of dissimilar materials, proper pin offsets of 2 and 2.5 mm due to sufficient however more research needs to be done to improve reaction [16]. the mechanical properties of the welds. Results from the work of Esmaeili et al [17] indicated that the optimum ultimate strength of the 11. FSW TOOLS USED FOR sound joint was achieved from a proper material flow ALUMINIUM AND BRASS and metallurgical bonding through a narrow intermetallic layer at the interface in addition to In most of the research work conducted on FSW crack detection by the ocBrassrrence of lamellar between aluminium and brass, the tool geometry composite structure (onion rings) in the stir zone and design is generally not fully disclosed which [17]. may be due to proprietary reasons. Although tool Ouyang et al [18] specifically found that different geometry is a very important factor for producing microhardness levels ranging from 136 to 760 HV0.2 sound welds. Rai et al [11] conducted a review on were produced in the weld nugget corresponding to FSW tools but did not provide much information on various microstructures, intermetallics and material FSW tools used for the joining of aluminium and flow patterns. brass in partiBrasslar. Nevertheless, few researchers Singh et al [26] found that in the horizontal disclosed the tools used in their studies to friction hardness profiles, the values were found to be about stir weld aluminium to brass. Akinlabi et al [33] 110 HV and 106 HV for brass and for the aluminium successfully welded 5754 and base metals respectively. The hardness values were brass by employing the threaded pin and concave stable for both metals in the HAZ and had tendency shoulder tool machined from H13 tool steel and to increase in the nugget zone and this can be hardened to 52 HRC. attributed to the formation of intermetallic

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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-5, 2017 ISSN: 2454-1362, http://www.onlinejournal.in

Abdollah-Zadeh et al [19] joined Aluminium alloy 1060 rolled plate to commercially pure brass with thicknesses of 4 and 3 mm using a SPK quenched and tempered tool steel and had a shoulder diameter of 15 mm with a threaded pin of 5 mm diameter and 6.5 mm long. Galvão et al [24] used conical and scrolled shoulder tools to weld oxygen-free brass with high phosphorous content (Brass-DHP, R 240) and AA 5083-H111. Whereas, Esmaeili et al [17] used a hot working alloy steel which was hardened to 45 HRC to weld AA 1050 to brass (BrassZn34). The cited tool used was composed of a 15 mm diameter shoulder and a tapered slotted pin [17]. Saeid et al [20] produced weld between rolled plates of 1060 aluminum alloy Fig.3 friction stir welded plates and commercially pure brass by using a quenched 13.Microstructural Evolution and X-ray and tempered tool steel. The tool had a 15 mm diameter shoulder and a left-hand threaded pin Diffraction Analysis mm). (φ5mm×6.5 The development of laboratory Furthermore, Li et al [31] used a tool with a work on the friction stir welding of dissimilar concaved shoulder and a cone-threaded pin of 16 materials will provide a good insight on their mm in diameter and possible industrial application and therefore enhance 5.2 mm in diameter respectively. The tool pin industrial development. Observed while welding was 2.75 mm in length to weld pure brass and AA brass and Aluminium the distribution between the 1350. brass and Aluminium (Al) has an evident boundary Agarwal et al [25] used a tool made of AISI H13 and the material in the stir zone shows obvious tool steel and High Speed Steel (HSS) and had a plastic combination of both materials. Furthermore, shoulder 18 mm and 15 mm in diameter and the tool observed clearly an onion ring structure in the stir pin 7 mm in diameter and 3.7 mm pin length [25]. zone indicating good material flow. Additionally, The above cited tool was used to weld AA 6063 to indicating that the metal brass and Al close to the commercially pure brass plates. Guerra et al [28] brass side in the Weld Nugget (WN) zone showed a successfully joined AA 6061 with a thin high purity lamellar alternating structure characteristic. brass one-piece pin and shoulder from D2 tool steel However, a mixed structure characteristics of brass heat treated to HRC62. The nib was 6.3 mm and Al existed in the aluminium side of the weld diameter and 5.8 mm long with standard 0.25/20 nugget (WN) zone. The stir action of the tool, right-hand threads and 19 mm diameter shoulder. frictional heat and heat conductivity of brass and Al FSW tools are of importance in successfully joining could have induced the different structures of both similar and dissimilar materials because tools sides in the weld nugget zone. The X-ray diffraction produce the thermomechanical deformation and (XRD) analysis showed that there were no new workpiece frictional heating necessary for friction Brass–Al intermetallics in the weld nugget zone. stirring. Therefore, it is necessary to further improve Consequently, the structure of the weld nugget zone the FSW tool geometry especially for dissimilar was largely plastic diffusion combination of brass materials to produce high quality welds and Al.

12. RESULTS AND DISBRASSSSION Welding Appearance Welds were obtained according to the experimental design with using filler materials and without filler materials. All welds were defect free. The intermixing of metals was also found in the welded samples. During the FSW process, the materials were transported from the advancing side to retreating side behind the pin where the weld was formed. Hardness of the brass was larger than the aluminium, and due to the pin stirring action the aluminium gets displaced in the weld.

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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-5, 2017 ISSN: 2454-1362, http://www.onlinejournal.in

the enhancement of the industries. Thus, the use of the FSW technique to join aluminium and brass alloys and material shapes is of importance in the development of their industrial applications.

In summary, the review of the friction stir welding of dissimilar materials foBrasssing on aluminium and brass has been successfully conducted. This will provide a comprehensive insight for the Brassrrent and also provide the Brassrrent state of research on FSW between aluminium and brass in order to fill the gaps with new research approaches and ideas.

Furthermore, new studies on FSW between aluminium and brass with respect to the process optimization and selection of cost effective FSW tools to produce sound welds still needs to be developed.

REFERENCES

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