The document discusses friction stir processing (FSP) which is a solid state technique used to modify the microstructure and mechanical properties of aluminium and its alloys. FSP is used to fabricate an aluminium metal matrix composite (AMMC) reinforced with nano Al2O3 particles. The objectives are to characterize the mechanical, structural and tribological properties of the fabricated AMMC. AA5083-H111 aluminium alloy will be processed using optimized FSP parameters such as tool design, rotational speed and transverse speed. The synthesized nano Al2O3 powder will be added to AA5083-H111 and stirred to produce the AMMC. Tests will then evaluate the microhardness, tensile strength
Aluminium Matrix Composites (AMC’s) are widely used in aerospace, automotive,
structural and marine applications due to their high strength to weight ratio, corrosion
resistance. In AMC one of constituent is aluminium or its alloy which forms a network
called as matrix phase and other constituent is embedded in matrix made of harder material
generally ceramic or non metallic material called as reinforcement. Various processing
techniques are available for manufacturing of AMC’s. Stir casting is one of the economical
and extensively used methods to enhance attractive properties of AMC’s. This paper
presents an overview of stir casing process, process parameter and preparation of AMC
using aluminium alloy as matrix phase and alumina (Al2O3) as reinforcement by varying
their proportion.
A STUDY ON MECHANICAL PROPERTIES OF ALUMINUM 6063 BASED HYBRID COMPOSITESSuryamech5
1.Hybrid metal matrix composites were successfully fabricated using stir casting method.
2.Reinforcement particles such as Silicon carbide and graphite were uniformly distributed in Al matrix.
3.The hardness and tensile strength of the composite is greatly increased with increasing of graphite particles in Aluminium matrix.
4.When adding constant 5% of Sic carbide, the tensile strength is increased.
Aluminium Matrix Composites (AMC’s) are widely used in aerospace, automotive,
structural and marine applications due to their high strength to weight ratio, corrosion
resistance. In AMC one of constituent is aluminium or its alloy which forms a network
called as matrix phase and other constituent is embedded in matrix made of harder material
generally ceramic or non metallic material called as reinforcement. Various processing
techniques are available for manufacturing of AMC’s. Stir casting is one of the economical
and extensively used methods to enhance attractive properties of AMC’s. This paper
presents an overview of stir casing process, process parameter and preparation of AMC
using aluminium alloy as matrix phase and alumina (Al2O3) as reinforcement by varying
their proportion.
A STUDY ON MECHANICAL PROPERTIES OF ALUMINUM 6063 BASED HYBRID COMPOSITESSuryamech5
1.Hybrid metal matrix composites were successfully fabricated using stir casting method.
2.Reinforcement particles such as Silicon carbide and graphite were uniformly distributed in Al matrix.
3.The hardness and tensile strength of the composite is greatly increased with increasing of graphite particles in Aluminium matrix.
4.When adding constant 5% of Sic carbide, the tensile strength is increased.
Experimental Study of Wear Rate Coefficient of Aluminium Hybrid Composites Ma...AM Publications
In current decade, demand in material characteristics like light weight, superior strength to weight ratio, improved surface properties and enhanced wear resistance for complex engineering applications like automobile, aerospace and nuclear are researcher’s interest. However, performance of hybrid composites depends on right combination of reinforcements. Silicon carbide, silicon nitride, boron nitride and titanium carbide are few reinforcements available at present. In this work, Al356 is reinforced with SiC and B4C to enhance the mechanical properties, surface hardness and wear resistance. This hybrid composite is prepared by stir casting technique and the morphology of composite is studied using optical microscope to investigate the dispersion of reinforcements. In the present study, the wear and friction characteristics of hybrid composites are investigated using pin on disc dry wear tests by varying the load and speed and the results are tabulated for load vs mass loss, load vs wear rate and load vs wear coefficient. The results report that wear rate of hybrid composites are lower than that of binary composites. Mechanical properties, surface hardness and wear characteristics of aluminium hybrid composites are compared with that of aluminium binary composites available at present.
Design and Fatigue Failure Analysis of hybrid fiber metal laminated Leaf SpringBharaniTharan12
A study on the fatigue strength of fiber reinforced hybrid epoxy composites was evaluated in this paper. The fiber metal laminates are hybrid composite materials are made from interlacing layers of thin metals and fiber reinforced plastics. The flexural strength of hybrid fiber metal composites was investigated from the three point bending test in accordance with ASTM D790-03 at various hybrid ratios of sequence layer in FML composites. The Glass fiber, Kevlar fiber and aluminum were taken for laminating the composite and reinforced with epoxy matrix. The adhesion property of fiber metal composites was enhanced by modified aluminium surface treatments and kevlar surface is treated with epichlorohydrin re-treatment. The interfacial fracture toughness were investigated from ASTM D5528-01. The flexural modulus and strain to failure results have been showed for various hybrid combinations, which have more effect on interlaminar strength of GARALL composites and improved fatigue life of leaf spring
ER Publication,
IJETR, IJMCTR,
Journals,
International Journals,
High Impact Journals,
Monthly Journal,
Good quality Journals,
Research,
Research Papers,
Research Article,
Free Journals, Open access Journals,
erpublication.org,
Engineering Journal,
Science Journals,
Design and Fabrication of a Stir Casting Furnace Set-UpIJERA Editor
Now-a-days a large variety of heating techniques/furnaces are available. There may be many method for supplying heat to the work but heat is produced either by combustion of fuel or electric resistance heating. Taking into consideration the effect of cost, safety, simplicity and ease of construction we are going for an electrical resistance heating furnace with indirect heating provisions. The stir casting furnace has two main parts that enable to perform all its operations, they are: Furnace Elements and Control Panel. This paper shows the design and fabrication of stir-casting furnace and aluminium melted and casted to form.
A Study on Mechanical Properties of Aluminium Alloy (LM6) Reinforced with SiC...IOSR Journals
This work deals with fabricating or producing aluminium based metal matrix composite and then
studying its microstructure and mechanical properties such as tensile strength, impact strength and wear
behavior of produced test specimen. In the present study a modest attempt has been made to develop aluminium
based MMCs with reinforcing material, with an objective to develop a conventional low cast method of
producing MMCs and to obtain homogeneous dispersion of reinforced material. To achieve this objective stir
casting technique has been adopted. Aluminium Alloy (LM6) and SiC, Fly Ash has been chosen as matrix and
reinforcing material respectively. Experiment has been conducted by varying weight fraction of Fly Ash ( 5%
and 15%) while keeping SiC constant(5%). The result shown that the increase in addition of Fly Ash increases
the Tensile Strength, Impact Strength, Wear Resistance of the specimen and decreases the percentage of
Elongation
Seminar on tribological behaviour of alumina reinfoeced composite material na...Sidharth Adhikari
THIS SEMINAR IS ON TRIBOLOGY BEHAVIOR OF ALUMINA REINFOCED COMPOSITE MATERIAL AND BRAKE DISK MATERIAL
MTECH SECOND SEMESTER SEMINAR ,CENTRE FOR ADVANCE POST-GRADUATE STUDIES,BPUT,ROURKELA
Elevated Temperature Uniaxial Mechanical Compression Examination and Hot Roll...IJERA Editor
Steel material may be considered one of the most significant materials in different mechanical engineering applications because it is the foremost component in the different mechanical industries and structure of buildings . Boron steels are suitable for varied applications , Diverse elements of metals have been alloyed to steel to attain definite properties for definite uses. . For example, molybdenum can typically be used as such an alloy to ensure high strength value for low steels alloys to improve its properties, such as the mechanical properties. These grades are useful to variety of industries since improving the mechanical properties of steel will increase its performance In this paper, the Gleeble, hardness test, including the microstructure before and after hot stamping, will be discussed; where the stress-strain must be defined in a specific temperature range. This paper also aims to show accurate TTT and CCT diagrams for three grades that have been studied, which are steel 50, steel 52, and steel 53.
Experimental Study of Wear Rate Coefficient of Aluminium Hybrid Composites Ma...AM Publications
In current decade, demand in material characteristics like light weight, superior strength to weight ratio, improved surface properties and enhanced wear resistance for complex engineering applications like automobile, aerospace and nuclear are researcher’s interest. However, performance of hybrid composites depends on right combination of reinforcements. Silicon carbide, silicon nitride, boron nitride and titanium carbide are few reinforcements available at present. In this work, Al356 is reinforced with SiC and B4C to enhance the mechanical properties, surface hardness and wear resistance. This hybrid composite is prepared by stir casting technique and the morphology of composite is studied using optical microscope to investigate the dispersion of reinforcements. In the present study, the wear and friction characteristics of hybrid composites are investigated using pin on disc dry wear tests by varying the load and speed and the results are tabulated for load vs mass loss, load vs wear rate and load vs wear coefficient. The results report that wear rate of hybrid composites are lower than that of binary composites. Mechanical properties, surface hardness and wear characteristics of aluminium hybrid composites are compared with that of aluminium binary composites available at present.
Design and Fatigue Failure Analysis of hybrid fiber metal laminated Leaf SpringBharaniTharan12
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ER Publication,
IJETR, IJMCTR,
Journals,
International Journals,
High Impact Journals,
Monthly Journal,
Good quality Journals,
Research,
Research Papers,
Research Article,
Free Journals, Open access Journals,
erpublication.org,
Engineering Journal,
Science Journals,
Design and Fabrication of a Stir Casting Furnace Set-UpIJERA Editor
Now-a-days a large variety of heating techniques/furnaces are available. There may be many method for supplying heat to the work but heat is produced either by combustion of fuel or electric resistance heating. Taking into consideration the effect of cost, safety, simplicity and ease of construction we are going for an electrical resistance heating furnace with indirect heating provisions. The stir casting furnace has two main parts that enable to perform all its operations, they are: Furnace Elements and Control Panel. This paper shows the design and fabrication of stir-casting furnace and aluminium melted and casted to form.
A Study on Mechanical Properties of Aluminium Alloy (LM6) Reinforced with SiC...IOSR Journals
This work deals with fabricating or producing aluminium based metal matrix composite and then
studying its microstructure and mechanical properties such as tensile strength, impact strength and wear
behavior of produced test specimen. In the present study a modest attempt has been made to develop aluminium
based MMCs with reinforcing material, with an objective to develop a conventional low cast method of
producing MMCs and to obtain homogeneous dispersion of reinforced material. To achieve this objective stir
casting technique has been adopted. Aluminium Alloy (LM6) and SiC, Fly Ash has been chosen as matrix and
reinforcing material respectively. Experiment has been conducted by varying weight fraction of Fly Ash ( 5%
and 15%) while keeping SiC constant(5%). The result shown that the increase in addition of Fly Ash increases
the Tensile Strength, Impact Strength, Wear Resistance of the specimen and decreases the percentage of
Elongation
Seminar on tribological behaviour of alumina reinfoeced composite material na...Sidharth Adhikari
THIS SEMINAR IS ON TRIBOLOGY BEHAVIOR OF ALUMINA REINFOCED COMPOSITE MATERIAL AND BRAKE DISK MATERIAL
MTECH SECOND SEMESTER SEMINAR ,CENTRE FOR ADVANCE POST-GRADUATE STUDIES,BPUT,ROURKELA
Elevated Temperature Uniaxial Mechanical Compression Examination and Hot Roll...IJERA Editor
Steel material may be considered one of the most significant materials in different mechanical engineering applications because it is the foremost component in the different mechanical industries and structure of buildings . Boron steels are suitable for varied applications , Diverse elements of metals have been alloyed to steel to attain definite properties for definite uses. . For example, molybdenum can typically be used as such an alloy to ensure high strength value for low steels alloys to improve its properties, such as the mechanical properties. These grades are useful to variety of industries since improving the mechanical properties of steel will increase its performance In this paper, the Gleeble, hardness test, including the microstructure before and after hot stamping, will be discussed; where the stress-strain must be defined in a specific temperature range. This paper also aims to show accurate TTT and CCT diagrams for three grades that have been studied, which are steel 50, steel 52, and steel 53.
Extraction of Silver From Photographic Waste--and their toxic effects and analysis of the amount is silver extracted from x-ray waste,methods of analysis of amount of toxic silver
6.a fuzzy based sfcl for fault current limiter in distribution system (2)EditorJST
In the modern power system, as the utilization of electric power is very wide, and it is very easy for occurring any fault or disturbance, which causes a high short circuit current flows. More over the increase in the power generation results in an increase in the system fault current levels. The high current due to this fault large mechanical forces and these forces causes overheating of the equipment. If the large size equipment are used in power system then they need a large protection scheme from severe fault conditions. Generally, the maintaince of electrical power system reliability is more important. But the elimination of fault is not possible in power systems, so, the only alternate solution is to reduce the fault current levels. For this a fuzzy based Super Conducting Fault Current Limiter is the best electric equipment which is used for reducing the severe fault current levels. In this paper, we simulated the unsymmetrical faults with fuzzy based superconducting fault current limiter. In our analysis we had the following conclusions.
Presentation about the article written by Hans Peter Schöner at the Magazine Elsevier: Control Engineering Practice, done for the class "Design of Mechatronic Systems" at the Benemerita Universidad Autonoma de Puebla. It includes the definition of Mechatronics, the diference between an automated system and a mechatronics one, the actual mechatronic systems in the vehicles and the limitations for the future development of the automotive industry which can be solved using Mechatronic with a proposed Development process.
Hello every one,
Here we attach our project report about processing of waste plastics and convert them in to useful form of energy.
here follows a video guide of our project on youtube
https://www.youtube.com/watch?v=-hFbNdWyPDo
A Review on Optimization of the Process Parameters in Friction Stir Welding o...IJAEMSJORNAL
This study is describing a simple and systematic methodology for optimizing the Process parameters of friction stir welding (FSW) of (AA6105 and AA6082) aluminium alloy using Taguchi technique. The main focus of this review paper is to discuss FSW principle, process parameter and mechanical properties. The current study focuses on the friction stir welding of wrought aluminium alloys 6082 and aluminium alloy 6105 that are commonly used in the structural and automotive industries. Apart from this paper FSW process has been done on various aluminium alloys but dissimilar friction stir welding of these two materials are not reported in their research. A systematic study has been performed on the joint properties on the dissimilar welding of the selected materials and their relationships between various parameters.
Evaluation Of Factors Affecting Sliding Wear Behaviour Of Al-Flyash Metal Mat...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
Alternative Joining Methods in Car Body Productiontheijes
The optimization of a car body in terms of cost can be achieved by using different materials in various positions of the car in order to utilize specific properties of each different material. The paper deals with the methods of mechanical joining used in car body production as alternatives to the most used conventional resistance spot welding. Load-bearing capacities of the joints made by mechanical joining and resistance spot welding of various materials used in car body structures are compared. The mechanical joining is mainly used to join material with various thicknesses, mechanical properties, surface coatings, even ferrous or non-ferrous metals.
Evolution of automobile production has been driven by competitive materials. Light-weight alloys are
continuously developed as most sustainable for automotive sector. Aluminum is being used as a successful
material in automotive applications due to its low weight, higher strength, good corrosion resistance and
formability to suit different design requirements. Since aluminium has the potential to be used as replacement
of the current automotive materials like steel and cast iron, its demand has increased greatly. In a further
development aluminium metal matrix composites (MMCs) were developed and these have improved wear
resistance, high fatigue strength and better thermal stability, as compared with those of aluminum. In
automobile sector, wear is a major problem, specifically in engineering assemblies and materials used for this
purpose should have good tribological properties. To this effect Al MMCs have attracted significant attraction
since they have improved wear resistance. Metal matrix composites are usually produced with secondary
particles in the form of either continuous or discontinuous fiber or particles. From the viewpoint of good
mechanical properties aluminium matrix is generally reinforced by oxide or carbide, nitride or boride
ceramics (like Al2O3, SiC, Si3N4, TiC, TiB2. Reinforcement of the matrix with only one of these
reinforcements may not yield desired properties and the matrix may need to be augmented with other
reinforcements also. Graphite and SiC are the reinforcements used widely in automotive industries to achieve
better mechanical and tribological properties and dampen the vibrations with less operational costs.
Aluminum metal matrix composite can be produced by various methods including powder metallurgy,
conventional casting technology, etc. Among the casting methods semisolid processing of composites yields
better mechanical strength. This review deals with various manufacturing methods of metal matrix composites
processing and insight on semisolid processing and its process parameters.
STUDIES ON ALUMINIUM-SILICON EUTECTIC ALLOY CASTING AND DESIGN APPROACH OF IT...IAEME Publication
LM-6 alloy, an eutectic alloy of Aluminium and Silicon is widely used in automobile industries and aircraft industries due to its high strength to weight ratio, high wear resistance, corrosion resistance etc. In this project work, to improve the mechanical properties of LM-6 alloy such as tensile strength, hardness and percentage elongation, modification treatment is carried out along with grain refinement, fluxing and degassing. Modification is a treatment of metal in molten condition which leads to the formation of fine grain structure improves the mechanical properties of the metal.
Synthesis And Characterization of Aluminum –Silicon-Fly Ash Composite By Stir...IRJESJOURNAL
Abstract :- In this work aluminium 7075 as matrix and silicon carbide and fly ash as reinforcements has been used. The %wt of reinforcement are varied to study the difference in aluminium property. Following are the samples are aluminium 7075 as 100%, aluminium 7075 90% + 10% SiC, and aluminium 7075 90% + 10% fly ash. The materials are obtained by stir casting technique. During casting 300 grams of aluminium has been taken as sample 1. 270grams of aluminium has been taken with 30grams of SiC as sample 2. The third sample is the mixture of 270grams of aluminium with 30grams of fly ash. Then the materials are made in the form of cylindrical rod of 30mm diameter and max length of 70mm. The composites are analysed for the mechanical study and the results are obtained based on hardness and the work has been extended to study the micro structure of the specimen by SEM analysis and Chemical Conformation.
Development of WC-Feal Composite by Stir Casting MethodDr. Amarjeet Singh
In this paper author make an effort to develop a new
material for fulfill the need of present requirement. This
material is developed by the using of stir casting method. A
AMMC’s composite are developed to fulfill the need of present
requirements. This composite material is prepared by the use
of 3 metals. These metals are iron (Fe), aluminum (Al) and
tungsten carbide (WC).Thus this composite come under metal
matrix composite. This composite is WC – FeAl composite.
This is prepared by the use of stir casting method. The base
metals are iron and aluminum. These are having equal
quantity by weight. In this the sample is prepared by the
change the of percentage reinforcement. This is varying from
0 to 3%. A test is conduct to check their tensile strength as
well as compressive strength. By these test it is confirm that
with the increase the percentage of reinforcement in the
composite their tensile strength is decrease but their
compressive strength is increase.
Analysis of Mechanical and Metallurgical properties of Al-SiCp Composite by S...IJRES Journal
Composites are one of the recent trends of interest in present material innovations. Mostly metal matrix composites (MMCs) have found its applications in aerospace and automobile industries. This is because of its highly attractive properties like low density, high strength, high temperature resistance, higher strength to weight ratio. Even though it has superior properties it faces several hurdles like high cost of production, poor dispersion of reinforcement material on the matrix. A study has been made to solve this problem by forming a metal matrix composite which has Aluminium (Al-97.47% C.P) has been the matrix material and Silicon Carbide (SiC- 31.5-32μm) been a reinforcement material. A new technique, Squeeze-Cum-Stir Casting, a method used to solve the problems faced in today‘s MMC production process. The experiments have been made by varying the volume fraction of SiC (5%, 15%, and 25%), while keeping all other parameters constant. Parameters like hardness, impact strength, and ultimate tensile strength were analyzed and observed and Scanning Electron Microscopy (SEM) analysis was performed.
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Project report on ammc's fabricated by friction stir process
1. DEPT, MECHANICAL SEACET 1
AMMCS
INVESTIGATION OF MECHANICAL, STRUCTURAL
AND TRIBOLOGICAL PROPERTIES OF ALUMINIUM
METAL MATRIX COMPOSITE (AMMC’S) FABRICATED
BY FRICTION STIR PROCESSING
2. DEPT, MECHANICAL SEACET 2
AMMCS
CHAPTER-1
SYNOPSIS:
Aluminium has any attractive properties compared to steel used in
aerospace, automobile, marine and other industries. Due to their high strength and
light weight, appearance, frabricability and corrosionresistance. The requirement
of excellent properties such as high specific strength, superior wear resistance,
and low thermal expansion has empathized. The use of aluminium metal matrix
composite, friction stir processingis a solid state technique based on principle of
friction stir welding is used for material processing in order to modify
microstructure and mechanical properties. The non-consumable tool rotates and
simultaneous. The tool has downward force that pushes it again the joint and
linear that permit it to complete the process.
In the presence, AA5083-H111/Nano Al2O3 AMC (aluminium
matrix composite) will be produced byfriction stir process technique, in order to
investigate the mechanical, structural and tribological properties.
The optimised parameters will be considerbased onliterature AA5083-H111 that
is rotational speed of 1000RPM , welding / transvers speed 40mm/min straight
square tool pin profile. After processing the test specimen will be prepared to
ASTM to evaluate the micro hardness and tensile properties also microstructure
the processed AMC‘s will be studied.
KEYWORDS:
Aluminium metal matrix composites, hardness, tensile strength,
friction stir processing weld structure.
3. DEPT, MECHANICAL SEACET 3
AMMCS
CHAPTER-2
INTRODUCTION
Friction stir processing (FSP)
It is a method of changing the properties of a metal through intense,
localized plastic deformation. This deformation is produced by forcibly inserting
a non-consumable tool into the work piece, and revolving the tool in a stirring
motion as it is pushed laterally through the work piece. The precursor of this
technique, friction stir welding, is used to join multiple pieces of metal without
creating the heat affected zone typical of fusion welding.
When ideally implemented, this process mixes the material without
changing the phase (by melting or otherwise) and creates a microstructure with
fine, equated grains. This homogeneous grain structure, separated by high-angle
boundaries, allows some aluminium alloys to take on superplastic properties.
Friction stir processing also enhances the tensile strength and fatigue strength of
the metal. In tests with actively cooled magnesium-alloy work pieces, the micro
hardness was almost tripled in the area of the friction stir process.
Process
In friction stir processing (FSP), a rotating tool is used with a pin and a shoulder
to a single piece of material to make specific property enhancement, such as
improving the material’s toughness or flexibility, in a specific area in the micro-
structure of the material via fine grain of a second material with properties that
improve the first. Friction between the tool and work pieces results in localized
heating that softens and plasticizes the work piece. A volume of processed
material is produced by movement of materials from the front of the pin to the
back of the pin. During this process, the material undergoes intense plastic
deformation and this results in significant grain refinement. FSP changes
4. DEPT, MECHANICAL SEACET 4
AMMCS
physical properties without changing physical state which helps engineers create
things such as “high-strain-rate super plasticity”. The grain refinement occurs on
the basematerial improving properties ofthe first material, while mixing with the
second material. This causes for the base material’s properties. This allows for a
variety of materials to be altered to be changed for things that may require other
difficult to acquire conditions. The processes branches off of friction stir welding
(FSW) which uses the same process to weld two pieces of different materials
together without heating, melting, or having to change the materials’ physical
state. Fig 2.1 shows process of friction stir process
FIG 2.1 SHOWS THE PROCESS BEHIND FRICTION STIR
PROCESS
5. DEPT, MECHANICAL SEACET 5
AMMCS
CHAPTER-3
OBJECTIVES:
I. To summarize the composite of friction stir processing technology.
II. Prepare design matrix to trial run of friction stir processingusing design of
experiments which varies welding parameters.
III. Preparation of Nano powders using anyone available synthesis technique.
IV. Fabrication of weldment with reinforced or doping. Nanoparticle into
matrix material using optimal speed, transvers speed, tool pin profile or
characterisation of friction stir processing joints.
V. Characterisation of mechanical, structural and tribological properties of
friction stir processing joints.
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CHAPTER-4
APPLICATION OF AA5083-H111
Shipbuilding
Vehicle bodies
Pressure vessels
Marine applications
Drilling rings
Transportation equipment’s
TV and communication towers
SHIPBUILDING
The application of aluminium alloys is increasing in all the industries
due to its combination of properties as
Low weight
Good mechanical resistance and
Good corrosion resistance
One of the industries where the application of aluminium is becoming
more important is shipbuilding which is one of main responsible for the transport
of people and goods in the world. The need of fast and less expensive ships,
demands for the advantages of Friction Stir Welding (FSW). Typically,
shipbuilding applies wrought aluminium alloys of series 5XXX and 6XXX. The
transfer of the FSW into industrial applications, such as shipbuilding, demands
for a detailed investigation about the influence of corrosionin the performance of
both parent materials and welded joints. The main mechanisms of corrosionthat
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have been evaluated in AA5XXX are the intergranular corrosion and the
exfoliation. (1)
Fig. High speed aluminium ferry containing numerous friction stir welded
components. (Hydro Aluminium).
VEHICLE BODIES
Today, the new revolution in car design is the use of new materials
in the vehicle structure.
As fuel economy restrictions become tighter, manufacturers must
find new ways to meet them.
This has led them away from using so much steel in the vehicles,
and more and more are moving towards aluminum.
Aluminium is about 3 times lighter than steel per unit volume, but
can be made just as strong using certain alloys/shapes/bonding
methods.
Because ofthis, AL parts can bethicker, and thus stronger, than their
steel counterparts, all while weighing less.
The first production vehicle to move to an Al frame was the Audi
A8 in 1994.
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This allowed Audi to make their full-size car lighter than the
competitions (BMW, Mercedes, Lexus...), thus giving them the edge
in performance & handling
While Al may seem like a miracle metal for car production, there is
a reasonnot all cars are made from Al... It costs alotmore than Steel.
The most obvious advantage to using aluminum in place of steel in
cars is aluminum weighs less.
Audi A8 Audi R8
PRESSURE VESSELES
DRILLING RINGS
The application opportunities of aluminium alloy drill pipe (ADP) in
geothermal drilling environments. With the improved development into ultra-
high energy extraction regions, the geothermal drilling industry is under high
demand and is being tested to drill deeper, faster, and at reduced costs in order to
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make geothermal competitive economically and to satisfy energy demands. The
achievement of greater drilling depths requires the advancement of the drilling
industry to address limitations in the weight capacity of the drill rigs and the
temperature limitations of the drilling components. Aluminium alloy drill pipes
(ADP), sometimes referred to as Lightweight Aluminium Drill pipes (LADP)
have been used in the drilling industry in Russia for many years. Due to ADP’s
lightweight and high strength to weight ratio there are several advantages over
conventional steel pipe. These advantages include the use of larger diameter drill
pipe with thicker walls which increase annular flow; reduced pressure loss inside
the drill pipe, resulting in smaller pump requirements; reduced derrick loads and
hook loads due to reduced weight per length compared to steel and increased
buoyancy effects in drilling fluids, resulting in smaller rigs or greater depth
penetrations with current rigs; and reduced stresses in a number ofdrilling design
parameters. The application ranges of ADP utilization was studied in regards to
temperature limitations, critical buckling loads and strength of materials,
geothermal fluid chemistry, drilling fluid pressure losses and hydraulics, load
comparisons, tool joint bonding, and economical cost analysis.(2)
FIG SHOWS DRILLING RINGS
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CHAPTER-5
Literature Survey
Friction stir welding;
Friction Stir Welding (FSW)is a solid-state welding process created and patented
by The Welding Institute (TWI) in 1991. It is a relatively novel joining
technology, which has caught the interest of many industrial sectors, including
automotive, aeronautic and transportation due to its many advantages and clear
industrial potential. The process adds new possibilities within componentdesign
and allows more economical and environmentally efficient use of materials. The
main advantage of FSW over traditional welding technologies is that joining is
achieved below the melting temperature avoiding deterioration of the material
microstructure and joint mechanical properties often seen in traditional welding,
and adding new dimensions to design and component optimization. Another
important consequence is that the problems related to the working environment
when using traditional arc welding processes, namely air pollution and ultraviolet
light are absent with FSW. Many lightweight materials and in particular
aluminum alloys may be joined by this technique, including the aluminum alloys
used in the civil engineering (5xxx and 6xxx series), which are difficult to join
by traditional welding techniques [3].
Properties of aluminium5xxx series;
5xxx Series. The major alloying element in 5xxx series alloys is mag- cesium.
When it is used as a major alloying element or with manganese, the result is a
moderate-to-high-strength workhardenable alloy. Magnesium is considerably
more effective than manganese as a hardener, about 0.8% Mg being equal to
1.25% Mn, and it can beadded in consider- early higher quantities. Alloys in this
series possess good welding characteristics and good resistance to corrosion in
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marine atmospheres. However, certain limitations should be placed on the
amount of cold work and the safe operating temperatures permissible for the
higher-magnesium alloys (over ~3.5% for operating temperatures above ~65 °C,
or 150 °F)to avoid susceptibility to stress-corrosioncracking. Figure 2 shows the
relationships between someof the more commonly used alloys in the 5xxx series.
[4]
AA5083-H111 series:
Aluminum Alloy 5083 is known for exceptional performance in extreme
environments. 5083 is highly resistant to attack by both seawater and industrial
chemical environments. Alloy 5083 also retains exceptional strength after
welding. It has the highest strength of the non-heat treatable alloys but is not
recommended for use in temperatures in excess of 65 °C.
MECHANICAL PROPERTIES OF AA5083-H111.
Tensile Strength 270 - 345 MPa
Hardness Brinell75 HB.
WELDABILITY OF AA5083-111:
Weld ability – Gas: Average
Weld ability – Arc: Excellent
Braze ability: Poor
Weld ability – Resistance: Excellent
FABRICATION OF AA5083-111:
Machinability: Poor
Workability – Cold: Average [3].
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GENERIC PHYSICAL PROPERTIES:
Density-2.65 g/cm³
Melting Point -570 °C
Thermal Expansion- 25 ×10−6 /K
Modulus of Elasticity- 72 GPa
Thermal Conductivity-121 W/m.K
Electrical Resistivity-0.058 ×10−6Ω.
Discussions regarding FS welds of AA5083-H111:
The AA 5083-H111 aluminum alloy, in combination with FSW, is at this moment
the most used alloy in the ship building industry and starting to be also more
present in the field of civil engineering. Because in the civil engineering field
there is not so much information about Aluminum and FSW, it is necessary to
have a good understanding ofthe process inthis direction. So, a series of research
programs are necessary to find some answers for the combination 5083-H111 +
FSW in the field of civil engineering, starting with simple elements as aluminum
plates.
It is known that the formation of friction stir welded zone is affected by the
material flow behavior under the action of the rotating tool. On the other hand,
the material flow behavior is direct influenced by the material properties such as
yield strength, ductility, hardness of the base material, tool design and FSW
parameters.
Usually, the friction stir welded joints are defect free joints since no melting takes
place during the welding process and the metals are joined in the solid state due
to the heat generated by the friction between the tool shoulder and components
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surfaces and flow of metal by the stirring process. The generated heat has to be
high enough to ensure a proper material flow in order to produce defect free
joints. Therefore the process parameters have to be in such manner combined to
produce the proper heat amount for a good joint. [3]
EXPERIMENTAL PROCEDURE:
A FSW tool made of high carbon and high chromium steel (HCHCr) having
straight square(SS)pin profile without draft was used to weld the alloys. The tool
had a shoulder diameter of 18 mm, pin diameter of 6 mm and pin length of 5.7
mm. The FSW tool was manufactured using CNC turning center and wire cut
EDM (WEDM) machine to get a accurate profile. The tool was oil hardened to
63HRC. Aluminum alloys AA6351-T6 and AA5083-H111 were used in this
work. Their chemical composition is shown in Table 1. Plates with dimensions
of 100 mm× 50 mm × 6 mm were prepared from the rolled plates. AA6351-T6
and AA5086-H111 alloys were respectively kept on the advancing side and
retreating side of the joint line. The FSW line was parallel to the rolling direction
of AA5083-H111 and perpendicular to the rolling direction of AA6351-T6. This
joint choice was made to induce the most severe mechanical combination . The
dissimilar butt welding was carried out on an indigenously built FSW machine .
Three joints were fabricated at three different welding speeds of 36, 63 and 90
mm/min. The rotational speed was kept as 950 r/min. After the welding process,
the joints were visually inspected for exterior defects and it was found that the
joints were free from any external defects. A specimen was cut from the welded
plate perpendicular to the FSW line to carry out the microstructural
characterization. The specimen was prepared as per standard metallographic
procedure and etched with modified Keller reagent followed by Wecks reagent.
[5]
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Fabrication of FSW Tool:
FEW tool made of High Speed steel having a pin profile of straight circular was
used to weld the joints. Toolhas a shoulder of diameter 14mm, a pin diameter of
4mm and a pin length of 4mm.
The design of the tool is a critical factor as a good tool can improve both the
quality of weld and the maximum possible welding speed . It is desirable that the
tool material is sufficiently strong, tough and hard at the welding temperature.
Effect of welding speed on microstructure and mechanical properties of friction
stir welded aluminum alloy was investigated by Sakthivel et.al. The influence of
FSW parameters on the grain size of the stir zone and the formability of friction
stir welded 5083 aluminum alloys was examined by Tomotake Hirata et.al. The
Aluminum plates were friction stir welded at various rotational speeds (850-
1860rpm) and travel rates of 30 to160 mm/min with welding forces ranging from
2.5 to 10 MPa, using different diameters welding heads was investigated byWang
and Liv [8]. From these experiments it has found that dimensions of the welding
head are critical to produce sound weld.
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CHAPTER-6
ADVANTAGES OF FRICTION STIR WELDING PROCESS
The process advantages result from the fact that the FSW process takes
place in the solid phase below the melting point of the materials to be
joined.
Friction stir welding can use purpose-design equipment or modified
existing machines tool technology.
Low shrinkage, even in long welds excellent mechanical properties in
fatigue, tensile and bend tests
No arc or fumes
No porosity
No spatter
Can operate in all position
Energy efficiency
No filler wire required
No gas shielding for welding aluminium
Can weld aluminium and copperof >75mm thickness in one pipe.(6)
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DISADVANTAGES OF FRICTION STIR WELDING PROCES
Large forces: order of magnitude 10 KN(backing plate required)
Rigid clamping system needed
Hole at the end if the weld
The problem if the weld gap greater than 10% material thickness
Investigation cost(equipment with high stiffness)
Licence cost
Other welds flams are possible
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CHAPTER-7
APPLICATIONS OF FRICTION STIR WELDING
Freezer panels
The first commercial application of friction stir welding concerned the
manufacture of hollow aluminium panels for deep freezing of fish on
fishing boats ( Figs 7.1 & 7.2). These panels are made from friction stir
welded aluminium extrusions.
FIG 7.1 shows Sapa FSW panel for pre-pressing of fish blocks before quick freezing. The
panel is Welded from both sides
FIG 7.2 shows Joint design of Sapa's freezer panels
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Panels for deck and wall construction
Pre-fabricated wide aluminium panels for high-speed ferryboats can be
produced by friction stir welding and are commercially available (Figs
(A) & (B)).
The panels are made by joining extrusions, which can be produced in
standard size extrusion presses. Compared to fusion welding.
The heat input is very low and this results in low distortion and reduced
thermal stresses.
Fig. (A). FSW catamaran side-wall with cut-out sections for windows at Marine Aluminium
in Haugesund, Norway
Fig. (B). Prefabricated FSW panel for half the width of the superstructure of a cruise liner
After welding the panels can be rolled for road transport, as they are stiff
only in the longitudinal direction (Fig(C)). When they can be transported
by ship, they can be stacked on top of each other (Fig (D)).
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Fig.(C). Prefabricated FSW panel for a catamaran sidewall, rolled for road transport
Fig. (D). Prefabricated FSW panel for a catamaran sidewall. Straight panel for ship
transportation at Marine Aluminium in Haugesund, Norway
(Thomas W M, Nicholas E D, Needham J C, Murch M G, Temple-Smith P and
Dawes C J (TWI): 'Improvements relating to friction welding'. European Patent
Specification
20. DEPT, MECHANICAL SEACET 20
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REFERENCE
1- Anderson, T.- New developments within the aluminium shipbuilding
industry.
2- Jellison M: Drill Pipe and Drill Stem Technology, Drilling Contractor,
March/April, (2007), 16-22.)
3- www.twi-global.com>friction-stir-welding