The document summarizes research on joining aluminum-titanium alloys using friction welding. It reviews 20 studies that investigated how friction welding parameters like friction pressure, time and speed affect properties of the welded joints. Most found that increasing speed or friction time and pressure initially improves tensile strength and reduces up to an optimum point, after which strength declines and intermetallic layers at the weld interface thicken. Controlling parameters is important to minimize brittle intermetallic formation and maximize joint strength.

1. STUDY OF FRICTION PRESSURE, FRICTION
TIME AND SPEED FOR Al-Ti ALLOYS IN RFW
Prepared by : Harsh B Joshi
(M.Tech Production Engineering, 2nd Semester)
Parul Institute of Engineering, Limda

2. PRESENTATION MAP
 INTRODUCTION
 LITERATURE RIVIEW
 CONCLUSION
 REFERENCES

3. INTRODUCTION
Friction welding is a solid state joining process that generates
heat through mechanical friction between workpieces in relative
motion to one another.
Friction
Welding
Liner
Friction
Welding
Rotary
Friction
Welding
Friction
Stir
Welding

4. ROTARY FRICTION WELDING

5. Now a days, increasing requirement to reduce the weight of
components,
 hybrid structures in transportation industries,
 Space ,
 including air and motor vehicles
 This has led to a requirement for an acceptable joining process
for dissimilar materials. Titanium–aluminum welds could have a
major applications in aerospace structures where high strength-to-
weight ratio is the primary requirement for higher fuel efficiency
and reduction in body weight.[1]

6.  Formation of a brittle intermetallic layer take place at the weld
interface when joining the dissimilar alloys.
 These IMC layers could lead to premature failure of the component.
 Critical IMC layer thickness is ~5 µm.[2]
 This IMCs plays important role in strength of the weld, This can be
controlled by analyzing the Friction time, Speed and Friction pressure in
RFW.[2]

7. RFW PROCESS

8. Applications and Advantages
 To join dissimilar materials and alloys
 Aerospace and automobile parts
 Industrial applications
 Environment friendly
 Less time for welding
 No filler material required

9. LITERATURE RIVIEW

10. Sr.
No
Title Author Name Journal Name Work Done Conclusion
1 Effect of
rotational speed
on Ti-6Al-4V-AA
6061 friction
welded joints
N.Rajesh
Jesudoss hyness
P shenbaga velu
Journal of
Manufacturing
processes (Feb
2018)
RFW of Ti-6Al-4V(16)
to AA6061(25),speed
1000 rpm , 5s ,attained
477degreeT, tensile
strength 186Mpa and 8
joule impact strenghth
was achieved
• TiAl3 produced
which is brittle
• Speed increases-
impact strength
decreases, increase in
intermetallic thickness
• Increase in axial
pressure- impact
strength decreases
2 Microstructures
characterisation
of rotary friction
welded AA6082
and
Ti-6Al-4V
dissimilar joints
M. Meisnar
S. Baker
J.M. Bennett
A.Bernad
A.Mostafa
S. Resch
A. Norman
N. Fernandes
Journal of
MATERIALS
AND DESIGN
(July 2017)
RFW of Ti-6Al-4V(8) to
AA6082(12) with speed
range 6000-14000rpm,
with Time of 3s, Friction
force 9-18 KN at 555
degree Temp. 310Mpa
strength was achieved
• aluminum side of
the weld was abraded
during the friction
process compared to
the harder titanium
side.
• No IMCs found

11. Sr.
No
Title Author Name Journal Name Work Done Conclusion
3 Assessment of
microstructure
and tensile
behavior of
continuous drive
friction welded
titanium tubes
R. Palanivel
I.Dinahar
R.F.Laubscher
Journal of
material
science and
engineering
(2017)
Ti alloys pipes 60mm
Dia.,75 mm length,
2200rpm , friction force
20kN, 32 s friction time
max UTS 338 Mpa was
achieved
•At 32 s max joint
efficiency 98.3%
achieved(24s,28s,32
s,36s,40s)
•Increase in F.T -
increase in UTS and
increase in
shortening (1.1 at
24s and 2.2 at 40s)
4 Microstructure
and mechanical
characterization
of continuous
drive friction
welded Grade
2 seamless
titanium tubes at
different
rotational speeds
D.G. Hattingh
R. Palanivel
I.Dinahar
R.F.Laubscher
Journal of
advances in
materials
science and
engineering
(2017)
Grade 2 Ti pipes, 60mm
dia., friction force 20kN ,
Forging time 22sec, at
different speeds of
(1600-283Mpa, 2200-
338Mpa, 2800-251Mpa )
UTS achieved
• As speed increases
UTS increases
• Shortening
increases with
increase in rpm
(1600rpm-1.1mm,
2800rpm-2.2mm)

12. Sr.
No
Title Author Name Journal Name Work Done Conclusion
5 Friction welding
of tungsten heavy
alloy with
aluminum alloy
Radosław
Winiczenko
Olgierd Goroch
Anna Krzy´nska
Mieczysław
Kaczorowskida
Journal of
material
processing
technology
(2017)
THA–AA of 20mm dia.,
100mm length joined by
RFW with FT 3.5s, FP
40Mpa, and 1450 rpm ,
234 strength of the weld
joint was achieved.
• Flash Dia.,
increases with
increase in FT
• UTS increases with
increase in FP and
FT.
• No Intermetallic
layers found.
6 An investigation
into the effect of
friction welding
parameters on
tensile strength of
titanium tubes by
utilizing an
empirical
relationship
R. Palanivel
I.Dinahar
R.F.Laubscher
International
measurement
confederation
(2016)
Grade 2 Ti pipes, 60
mm dia., joined by
RFW.
An empirical relation
was developed like
parameters speed ,
friction time on UTS.
• Size of the weld
flash increases with
increase in friction
time.
• Grain size in weld
zone reduces with
friction time.
(2.2micrometer -25,
1.3 micrometer –
39)

13. Sr.
No
Title Author Name Journal Name Work Done Conclusion
7 Characteristics of
friction welded
AZ31B
magnesium–
commercial pure
titanium
dissimilar joints
A.K.Lakshmin
R.Saranarayana
V. Karthik
Srinivasn
B. Venkatraman
Journal of
magnesium
and alloys
(2015)
Ti- Mg of 15mm dia.,
and 80mm length , speed
1100rpm, friction
pressure 20Mpa, Friction
time 4s the joint was
made with RFW.
• 15 micrometer of
intermetallic layers
formed in Mg side,
and weld joint may
fail in Mg side
because of the IMCs
formation
8 Friction Welding
of Aluminum and
Aluminum
Alloys with Steel
Andrzej
Ambroziak,
Korzeniowski,
KustroN,
Winnicki,
PaweB
SokoBowski,
HarapiNska
Journal of
advances in
materials
science and
engineering
(2014)
AlMg3- Ti with
1500rpm, pressure
(shortening speed)
69Mpa, friction time 2.4
,tensile strength 205.4
achieved
• Long time and high
temperature results in
formation of IMCs
•Al3Fe is brittle
interface
•AlFe is not brittle

14. Sr.
No
Title Author Name Journal
Name
Work Done Conclusion
9 Direct keyhole
laser welding of
aluminum alloy
AA5754 to
titanium alloy
Ti6Al4V
I.Tomashchuk
P. Sallamand
E. Cicala
P. Peyre
D.Grevey
Journal of
Materials
Processing
Technology
(2014)
AA5754- Ti6Al4V
plate of 2 mm thick
joined by Yb - YAG
laser welding of power
6kW and 600
micrometer spot
diameter accuracy.
• Shift of beam to
AA5754: UTS – 60%
of AA5754 (120Mpa)
• Shift of beam to
Ti6Al4V : Ti3Al
formed which is
brittle
• Centered beam :
Reduces UTS up to`
30-36% of AA5754
10 Yb-YAG laser
offset welding of
AA5754 and T40
butt
joint
Giuseppe Casalino
Michelangelo
Mortello Patrice
Peyre
Journal of
Materials
Processing
Technology
(2014)
Ti40- AA5754 plate of
2mm thickness welded
by Yb – YAG laser of
power1.50KW,with
1.80m/min welding
speed and 191Mpa of
UTS was obtained.
• No spatter and
porosity occurred
• Max. UTS was
obtained with .75mm
laser offset and
50J/mm energy
(131Mpa)

15. Sr.
No
Title Author Name Journal
Name
Work Done Conclusion
11 Investigation on
the Effect of
Friction Welding
Parameters on
Impact Strength
in Dissimilar
Joints
C.Shanjeevi,
J.Jeswin
Arputhabalan,
Rohan Dutta,
Pradeep
Journal of
material
science and
engineering
(2017)
• Cu- Ferrite SS of
25mm dia., was joined
by RFW .
• The max. Impact
strength achieved with
1500rpm, FP= 43Mpa .
• Increase in the FP
and speed – increase
in Impact strength
12 Metallurgical and
mechanical
properties of
continuous drive
friction welded
copper/alumina
dissimilar joints
Peng Li
Jinglong Li
Honggang Dong
Chengzong Ji
Journal of
materials
design (2017)
• Cu- Al of 14mm dia.,
was joined with
0.25mm of Al
interlayer by RFW.
• The parameters was
optimized FP= 12Mpa
FT=12s and max.
tensile strength of
35Mpa was achieved.
• AS increase in FP
and FT the tensile
strength reaches the
max value 35 Mpa
and then decreases.
• Interlayer of Al
0.47mm can give
maximum strength if
the weld joint from
results.

16. Sr.
No
Title Author Name Journal
Name
Work Done Conclusion
13 In-homogeneity
of microstructure
and mechanical
properties in
radial direction of
aluminum/copper
friction
welded joints
Longwei Pan, Peng
Li, Xiaohu Hao, Jun
Zhou,
Honggang Dong
Journal of
Materials
Processing
Technology
(2017)
Al-Cu of 10mm dia.,
was joined with
FP=75Mpa, Forging
pressure=100 Mpa,
FT= 5s, Speed=
1500rpm with RFW.
• Tensile strength
88Mpa and 20.2%
elongation achieved.
• After PWHT process
strength decreases.
• Tensile properties
decreases with
increase in IMCs
layer.
14 Application of
response surface
methodology to
optimize process
parameters in
friction welding
of Ti−6Al−4V
and SS304L rods
R. Kumar,
M.Balasubramanian
Journal of
Transactions
of non ferrous
metals society
of
china(2015)
Ti6Al4V – SS 304L
was jointed with Cu
interlayer and
parameter was
optimized, FP=
12Mpa,
speed=1500rpm,
FT=1.2S, forging
pressure= 40Mpa and
joint strength was 523
Mpa was achieved.
• Due to Cu interlayer
the Ti- SS bonding
was excellent.
• It was observed that
with optimized
parameter the
interlayer thickness
can be reduced.

17. Sr.
No
Title Author Name Journal
Name
Work Done Conclusion
15 Rotary friction
welding of
molybdenum
components
M. Stütza,
F. Pixnera,
J. Wagnerb,
N. Reheisb,
E. Raiserc,
H. Kestlerb,
N. Enzingera
International
Journal of
Refractory
Metals
& Hard
Materials
(2018)
12mm dia. Of Mo – 9
mm dia., of TZM was
joined by RFW.
Axial force = 35.6 KN,
RPM = 3200 , T= 350
degree was achieved.
• Temperature
increases very high in
Mo- TZM joining
• Axial pressure is
function of friction
time.
16 Two-pass Friction
Stir Welding of
Aluminum alloy
to Titanium alloy:
A Simultaneous
Improvement in
Mechanical
Properties
Amlan Kar, Satyam
Suwas and Satish V.
Kailas
Materials
Science &
Engineering
(2018)
Al2024- Ti6Al4V was
successfully joined by
FSW with tool
shoulder dia., 20mm ,
pin dia., 4 mm and 32
mm length.
• Tensile properties
were increased in 2nd
pass ( 231 – 271 Mpa,
and ductility 7.4- 9 )
• After second pass
more fine grains
achieved
• Intermetallic
compounds Al3Ti was
found at joint .

18. Sr.
No
Title Author Name Journal
Name
Work Done Conclusion
17 Effect of niobium
interlayer in
dissimilar friction
stir welding of
aluminum
to titanium
Amlan Kara,
Sounak
K. Choudhuryb,
Satyam Suwasa,
Satish V. Kailasa
Journal of
Materials
Characterizati
on
(2018)
Al- Ti ( grade 2) was
joined by FSW with
tool rotation speed
900rpm, travel speed=
90mm/min and offset
1.6 mm.
• Improvement in
tensile properties due
to fine grains
• Nb retarded the
formation of Al 3Ti.
•Ti and Nb was
homogeneously
distributed
18 Friction stir
welding of
titanium alloys: A
review
Kapil Gangwar,
M.Ramulu,
Journal of
materials
design ( 2017)
FSW Ti alloys with
different processing
condition and tool
design was observed.
• Increase in the
thickness of the plate
,use more rotational
and weld speed to get
better results.

19. Sr.
No
Title Author Name Journal
Name
Work Done Conclusion
19 High-frequency
linear friction
welding of
aluminum alloys
Hideo Mogami,
Tomoki Matsuda,
Tomokazu Sano,
Ryo Yoshida,
Hisashi Hori, Akio
Hirose
Journal of
materials
design
(2017)
High Freq. LFW at 250
Hz of Al 6063 –
Al5052 with FP=
30Mpa, Forging
pressure = 150 Mpa,
Forge time = 5s and
FT = (0.4 – 3.5) s
• Refined grain size
of about 10nm
(in SEM) was
observed
• Higher joint
strength
• Hardness reduces –
High input heat( more
processing time)
20 Friction stir
welding of
titanium alloy
TiAl6V4 to
aluminium alloy
AA2024-T3
Ulrike Dressler
Gerhard Biallas,
Alfaro Mercado
Journal of
Materials
Science and
Engineering A
(2009)
TiAl6V4 – AA2024T3
joined by FSW with
tool material Tool steel,
shoulder diameter
18mm, threaded and
tapered pin of 6 mm
dia., with rotational
speed 850rpm and
80mm/min weld speed
• Offset of pin toward
Al plate gives more
strength to weld
joints.
• UTS of joint
reached 73%(348
Mpa) of AA2024T3
base material strength.

20. Conclusion
On the basis of the above reviewed literatures the following
conclusions can be made ,for Al- Ti alloys ..
 The effect of the parameters FP, FT and rotational speed on UTS can
be derived as follow:
 As speed increases , impact strength and UTS increases up to certain
peak point and then decreases, and thickness of the intermetallic layer
increases.
 Increase in axial pressure cause decrease in the impact strength

21.  Increase in Friction Time increases UTS unto peak level and then
decreases, and increase the shortening (reduction in length in mm
per FT).
 Shortening increases cause increase in the UTS.
 Grain size in weld zone reduces with increment in friction time.
 In RFW process of Al-Ti alloys, the more thicker IMCs generation
cause failure of the weld joint because it is brittle. ( Al3Ti is brittle
in nature ).
 Using of any interlayer material ( Cu, Nb ) reduces the chances of
the formation of IMCs.
 The FP, FT and rotation speed is the function of the UTS.

22. REFERENCES[1] Amlan Kar, Satyam Suwas and Satish V. Kailas, Two-pass Friction Stir Welding of Aluminum alloy to Titanium
alloy: A Simultaneous Improvement in Mechanical Properties, Materials Science & Engineering ,
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Science & Engineering
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23. [7] A.K. Lakshminarayanan a, R. Saranarayanan a, V. Karthik Srinivas a, B. Venkatraman, Characteristics
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alloys
[8] Radosław Winiczenkoa, Olgierd Gorochb, Anna Krzy´nskac, Mieczysław Kaczorowskida, Friction
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chennai

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26. THANK YOU
For your carefully listening and attention..!