Top Banner

of 20

Friction Stir Welding (Fsw) 2

Apr 05, 2018

Download

Documents

hosseinidokht86
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
  • 8/2/2019 Friction Stir Welding (Fsw) 2

    1/20

    FRICTION STIR WELDING

    (FSW)Dissimilar welding of Al To stainless steel (304)

    HIGH INSTITUTE OF TECHNOLOGYMechanical Engineering Department

    Manufacturing Technology

    BANHA UNIVERSITY

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    2/20

    1. Abu Bakr Okasha Abdullah

    2. Ahmad Abdullah Ibrahim Abdullah

    3. Sameh Maher Fouad

    4. Sherif Ismail Sedky Abdoul.Maqsoud , Maraashly

    5. Emad Soliman Mostafa Muhammad

    6. Micheal Aziz Farag Atallah

    7. Muhammad Sobhy Soliman , Elshohady

    8. Muhammad Salah Muhammad, Fayssal

    9. Mahmoud Ibrahim Ahmad Muhammad

    Prepared By

    Group no. (6) 5th year

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    3/20

    Is to provide a new solid-state joining process. Thisjoining technique is energy efficient, environmentfriendly, and versatile. In particular, it can be used to

    join high-strength aerospace aluminum alloys and

    other metallic alloys likeStainless steel (304) that arehard to weld by conventional fusion welding. Also our objectives of our work were to:1. Optimize welding conditions & parameters such as

    tool pin geometry, rotational speed and travel

    speed.2. Study the effects of welding parameters on

    microstructure evolution and mechanical propertiesof welded joints of dissimilar Al to Stainless Steel(304).

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    4/20

    Experimental

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    5/20

    H12 Tool steel

    Pure Aluminum

    Stainless steel (304)

    To use these materials in our work such

    operations should be done firstly

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    6/20

    H12 Tool steel

    Heat Treatment1. Setting the furnace on 850 C and put pieces of coal.

    2. Put the tool inside the furnace and setting it on 1010 C.

    3. Keep the tool inside the furnace for 45 minutes after reaching 1010 C.

    4. Take out the tool and leave it cooled in air until room temperature.

    5. First Tempering: holding it in the furnace at 550 C for 60 minutes.

    6. Take out the tool and leave it cooled again in air until room temperature.

    7. Second Tempering: holding it in the furnace at 550 C for 60 minutes.

    8. Take out the tool and leave it cooled in air.

    Process characteristics1. Reduce residual stresses.

    2. Increase hardness.

    3. Improves toughness.

    4. Increases impact resistance

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    7/20

    Heat treatment operation curve of toolsteel H12

    0

    200

    400

    600

    800

    1000

    1200

    Temperature,

    C

    Time,minutes

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    8/20

    Tools geometry performed by machiningoperations

    Type (I) Tool: CylindricalPin

    Type (II) Tool: SquaredPin

    Type (III) Tool: TaperedPin

    Type (IV) Tool: HexagonalPin

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    9/20

    Material work piece

    Pure Aluminum

    Stainless steel (304)

    To Pack away them to be used in our worksome processes should be done like

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    10/20

    Material work piece

    1. Cleaning the sample mechanicallyusing stainless steel wire brush toremove rust.

    2. Cleaning the sample usingacetone to remove greaseand oils.

    3. Fixing the sample tightly on themilling machine.

    4. Starting FSW process.

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    11/20

    TESTS

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    12/20

    Microstructure Investigation

    Specimen Preparation

    Cutting the specimen. Grinding it using Al2O3 or SiC abrasive paper.

    Polishing. Etching.

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    13/20

    Microscopy

    Optical microscopy using metallographic microscopes is a

    widely used technique for analyzing metallographicspecimens. The typical magnification range for opticalmicroscopes is 50 to 1000X .

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    14/20

    Microstructure investigation of stainless steel Base metalof sample # 2

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    15/20

    Microstructure of sample #2 at WZ/Stainless steel (304)side of joint shows sound interface between stainlesssteel and aluminum when using cylindrical pin tool .

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    16/20

    Microstructure of Al/Stainless steel welded joint ofsample # 8A at the interface between st.st and weldzone, shows micro cracks at the interface

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    17/20

    Hardness Hardness Testing provides useful information, which can be correlated to tensile

    strength, wear resistance, ductility, and other physical characteristics of thematerial. Hardness testing is therefore useful for monitoring quality control andfor aiding in the materials selection process.

    The working principle of Vickers hardness testers employs only one indenter,being a pyramidal diamond with square base.After the indentation is made, the two diagonals will be measured and as these

    are almost never the same, the average value will be considered.the Vickers number is given by the relationship between the applied load and thesurface area of the indentation. In our process were 10Kg till 15 Sec.

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    18/20

    Hardness curve of Sample #2

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    19/20

    Hardness curve of sample # 7

  • 8/2/2019 Friction Stir Welding (Fsw) 2

    20/20