Author : S.R.Sundara Bharathi, A.Razal Rose and V.Balasubramanian

Friction Welding (FW) is a process of solid state joining which is used extensively in recent years due to its advantages such as low heat input, production efficiency, ease of manufacture and environment friendliness. Friction welding can be used to join different types of ferrous metals and non-ferrous metals, which are not easy to be welded by traditional fusion welding processes. The process parameters such as friction pressure, friction time, forging pressure, forging time, and rotating speed play the major roles in determining the strength of the joints. The main objective of this investigation was to apply friction welding for joining of 12mm dia aluminium alloy similar joints 2024 & 2024. In the present study an experimental friction welding setup, in which continuous drive friction welding used. At first optimum parameters were obtained to join parts having equal diameter and length through trail experiments. Trial experiments were conducted to determine the working range. The parameters were chosen in such a way that the friction welded joints should be free from any visible external defects. In the second part of the study, the effect of welding parameters on welding strengths was investigated. Later the mechanical properties of joints were examined by using tensile test, SEM fractograph analysis, macro & micro structure analysis and Vickers micro hardness test.

Keywords: Friction welding, Aluminium alloy 2024, Tensile strength, SEM Fractograph, Microstructure, Macrostructure and Vickers microhardness.

Article published in International Journal of Current Engineering and Technology, Vol.5, No.2 (April-2015)