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Resistance spot welding of Al6061 lap joints with a polyvinyl alcohol-bonded graphene interlayer

  • Velavali Sudharshan

    Velavali Sudharshan obtained his B. Tech in Mechanical Engineering from the REVA University (2019) and M. Tech from the National Institute of Technology, Calicut, (2021). His research interests include welding, material processing and characterisation.

         , Basil Kuriachen

    Basil Kuriachen is an Assistant Professor in the Department of Mechanical Engineering, National Institute of Technology, Calicut, since 2020. His vivacity and dexterity towards abiding commitment to sublime work ethics conferred him with a Ph.D. and M. Tech degree from the NIT, Calicut, (2015) and the Mahatma Gandhi University, Kottayam, (2011), respectively. His resolute research niches are in the field of metal additive manufacturing, micro- and nano-machining processes, precision and ultra-precision machining, modelling and analysis in the machining of difficult machine materials, tribology of manufacturing processes, nano-tribology, surface coatings, nano-lubricants, advanced machining processes, friction stir welding and processing and surface characterization.

         and Jinu Paul

    Jinu Paul obtained his B. Tech in Mechanical Engineering from the Mahatma Gandhi University (1999), M. Tech in Materials Science from the Indian Institute of Technology, Madras, (2001) and Ph.D. from the Nanyang Technological University (2005). He was working as a Research Fellow in the National University of Singapore during 2005–2009 and in the Nanyang Technological University during 2009–2012. He joined as an Assistant Professor in the department of Mechanical Engineering, Indian Institute of Technology, Kharagpur, in 2012. Currently, he is working as an Associate Professor in the National Institute of Technology Calicut. His research interests include material processing, welding and composites.

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Published/Copyright: April 7, 2022
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Materials Testing
From the journal Materials Testing Volume 64 Issue 4

Abstract

In order to increase the lap shear strength and weldability of aluminium alloy (Al6061), spot welding is done in lap configuration with an interlayer of graphene nano-platelets (GNPs). The GNPs are bonded using polyvinyl alcohol (PVA) and drop-casted on one of the mating surfaces of the lap joint before the resistance spot welding process. The experiment is carried out using different welding currents and time cycles at a constant load. It was found that the processing parameters and the presence of GNP interlayer play an important role in the performance of the lap joint. An increase of approximately 60% in the lap shear strength was observed with GNP interlayer at optimum processing conditions. Interfacial–microstructure characterisation was carried out across the fractured surface of the lap joint by using optical microscopy, scanning electron microscopy (SEM) and X-ray diffraction (XRD). An increase in hardness, a change in nugget diameter and the mode of failure were observed in the presence of the GNP interlayer. A detailed analysis of the possible weld strengthening mechanisms is included in this article.

Keywords: aluminium alloy (Al6061); graphene nano-platelets (GNPs); interlayer; lap joints; resistance spot welding
Corresponding author: Jinu Paul, Department of Mechanical Engineering, National Institute of Technology Calicut, Calicut-673601, India, E-mail:

Funding source: Department of Science and Technology (DST), Government of India

Award Identifier / Grant number: SR/FST/ETI-388/2015

About the authors

Velavali Sudharshan

Velavali Sudharshan obtained his B. Tech in Mechanical Engineering from the REVA University (2019) and M. Tech from the National Institute of Technology, Calicut, (2021). His research interests include welding, material processing and characterisation.

Basil Kuriachen

Basil Kuriachen is an Assistant Professor in the Department of Mechanical Engineering, National Institute of Technology, Calicut, since 2020. His vivacity and dexterity towards abiding commitment to sublime work ethics conferred him with a Ph.D. and M. Tech degree from the NIT, Calicut, (2015) and the Mahatma Gandhi University, Kottayam, (2011), respectively. His resolute research niches are in the field of metal additive manufacturing, micro- and nano-machining processes, precision and ultra-precision machining, modelling and analysis in the machining of difficult machine materials, tribology of manufacturing processes, nano-tribology, surface coatings, nano-lubricants, advanced machining processes, friction stir welding and processing and surface characterization.

Jinu Paul

Jinu Paul obtained his B. Tech in Mechanical Engineering from the Mahatma Gandhi University (1999), M. Tech in Materials Science from the Indian Institute of Technology, Madras, (2001) and Ph.D. from the Nanyang Technological University (2005). He was working as a Research Fellow in the National University of Singapore during 2005–2009 and in the Nanyang Technological University during 2009–2012. He joined as an Assistant Professor in the department of Mechanical Engineering, Indian Institute of Technology, Kharagpur, in 2012. Currently, he is working as an Associate Professor in the National Institute of Technology Calicut. His research interests include material processing, welding and composites.

  1. Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.

  2. Research funding: The authors received support from the Department of Science and Technology (DST), Government of India, for the research grant sanctioned under the scheme FIST (No. SR/FST/ETI-388/2015) through the aid of which this initiative was undertaken.

  3. Conflict of interest statement: The authors declare no conflicts of interest regarding this article.

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Published Online: 2022-04-07
Published in Print: 2022-04-26

© 2022 Walter de Gruyter GmbH, Berlin/Boston

Articles in the same Issue

  1. Frontmatter
  2. Effect of deep cryogenic treatment on microstructure and mechanical properties of a CoCrFeNiMo medium-entropy alloy
  3. Bilayer growth kinetics and tribological characterization of boronized AISI M2 steel
  4. Effect of graphene nanoplatelets on mechanical and impact properties of an aramid/glass-reinforced epoxy composite
  5. The effect of SiC content on microstructural and tribological properties of sintered B4C and SiC reinforced Al–Cu–Mg–Si matrix hybrid composites
  6. Effects of asymmetric tooth profile on single-tooth stiffness of polymer gears
  7. Hunger games search algorithm for global optimization of engineering design problems
  8. Alumina catalyst waste utilization for aluminum-based composites using the friction stir process
  9. Comparison of microstructure and wear behaviors of PTA coated AISI 304 with alumina, boron and ekaboron III powder
  10. Influence of testers on the ISE effect
  11. Crashworthiness design of heat treated vehicle parts with tailored properties
  12. Shape coefficient of impact-echo for small-size short cylinder/circular tube structures
  13. Resistance spot welding of Al6061 lap joints with a polyvinyl alcohol-bonded graphene interlayer
  14. Effect of reinforcement particle amounts on dry sliding wear behavior of shot-peened SiC/A356 composites
  15. Prediction and optimization of thrust force during the drilling of AISI 2080 steel
https://doi.org/10.1515/mt-2021-2073
Keywords for this article
aluminium alloy (Al6061); graphene nano-platelets (GNPs); interlayer; lap joints; resistance spot welding

Articles in the same Issue

  1. Frontmatter
  2. Effect of deep cryogenic treatment on microstructure and mechanical properties of a CoCrFeNiMo medium-entropy alloy
  3. Bilayer growth kinetics and tribological characterization of boronized AISI M2 steel
  4. Effect of graphene nanoplatelets on mechanical and impact properties of an aramid/glass-reinforced epoxy composite
  5. The effect of SiC content on microstructural and tribological properties of sintered B4C and SiC reinforced Al–Cu–Mg–Si matrix hybrid composites
  6. Effects of asymmetric tooth profile on single-tooth stiffness of polymer gears
  7. Hunger games search algorithm for global optimization of engineering design problems
  8. Alumina catalyst waste utilization for aluminum-based composites using the friction stir process
  9. Comparison of microstructure and wear behaviors of PTA coated AISI 304 with alumina, boron and ekaboron III powder
  10. Influence of testers on the ISE effect
  11. Crashworthiness design of heat treated vehicle parts with tailored properties
  12. Shape coefficient of impact-echo for small-size short cylinder/circular tube structures
  13. Resistance spot welding of Al6061 lap joints with a polyvinyl alcohol-bonded graphene interlayer
  14. Effect of reinforcement particle amounts on dry sliding wear behavior of shot-peened SiC/A356 composites
  15. Prediction and optimization of thrust force during the drilling of AISI 2080 steel
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