THE STRENGTH AND FRACTURE MORPHOLOGY OF SIMILAR AND DISSIMILAR CONTINUOUS DRIVE FRICTION WELDING

Hussein Mesmari; Fawzia Krayem

doi:10.66411/jer.v23i.305

Authors

Hussein Mesmari Department of Materials and Metallurgical Engineering, University of Tripoli, Libya Author
Fawzia Krayem Applied Research and Development Center, Libya Author

DOI:

https://doi.org/10.66411/jer.v23i.305

Keywords:

Taguchi L27, CDFW, AISI 304, Al 6061-T6, Tensile Strength, SEM, Fracture, Morphology

Abstract

Friction welding is a solid phase welding process that is used to join different types of ferrous and non-ferrous metals that cannot be joined by existing fusion welding methods. Continuous drive friction welding CDFW method appears to be an alternative method to make the use of stainless steel and Aluminum alloys more widespread. Friction time t1, friction pressure P1, and forge pressure P2 are being selected as design parameters, which have significant effect on the tensile strength of weld joints. Three levels Taguchi of 27 trials "orthogonal array L27 (33)" was adopted to analyse the effect of selected parameters. In the present study, preliminary experimental trials are conducted and used to determine the exact range of each selected parameter. The strength of produced friction joints exhibited comparable strength with the base material with maximum efficiency of 98% for AISI 304/304, and 89% for AISI 304/Al6061-T6 joints. For similar joints, The fracture mode as a microvoid coalescence at the fractured surface confirms the ductile mode of failure, while for dissimilar joints the fracture occurred at the weld line as an interface splitting. Many spiral patterns are observed, which acted as preferential failure sites during tensile testing, and as the numbers of spiral defects decreased, joint strength improved

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