Author : S. S. Deulkar, J. S. Sidhu and G. S. Lathkar

Joining of dissimilar materials is of increasing interest for a wide range of industrial applications. There are various welding methods that have been developed to obtain stable joints in various applications. However friction welding is a solid state joining process used to join similar and dissimilar metals, not possible with other available welding methods. Friction welding method has been used extensively in the manufacturing methods because of the advantages such as high material saving, low production time, no filler material, environment friendliness, lower heat affected zone and good welded joints produced. In present study, joining of dissimilar metals Al- 63400 alloy and Fe 410WA is carried out using different parameters on continuous drive friction welding process. Encouraging results were obtained with dissimilar materials with minimum axial shortening and reasonably good tensile strength. The process parameters like rotational speed, friction pressure, upset pressure and upset time were varied and friction time kept constant. Taguchi’s design for experiments is used for optimizing the welding parameters.

Keywords: Axial shortening, Friction welding, Tensile strength, Taguchi design