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Influence of tool geometry on mechanical and microstructural characteristics of friction stir welded cast alloys

  • B. S. Bindhushree

    B. S. Bindhushree is currently pursuing her Ph.D. Degree in Mechanical Engineering, Dayananda Sagar University, Bengaluru, India. She completed her M. Tech in Computer Integrated Manufacturing in 2019. Her research areas of interest are stir casting, machining and friction stir welding.

         , P. Sevvel

    P. Sevvel obtained his Ph.D. in Mechanical Engineering in 2016 and M.Tech Degree in Industrial Engineering in 2005. He has 17 years of experience. He is working as a Professor in Mechanical Engineering Department in S.A. Engineering College. 1 He has published 40 research papers in various SCI and Scopus indexed journals. His areas of research includes friction stir welding, additive manufacturing etc.

     EMAIL logo     , S. P. Shanmuganatan , D. Saravanabavan and M. Madhusudan
Published/Copyright: April 25, 2024
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Practical Metallography
From the journal Practical Metallography Volume 61 Issue 5

Abstract

Cast alloys find suitable applicability in aerospace sector owing to low porosity, high specific strength, corrosion resistance, fluidity and good machinability. The investigation focuses on friction stir welding (FSW) of cast A356 and A2014 alloys with varied range of process parameters, namely tool pin shape (cylinder, threaded cylinder, square, and conical), tool rotation speed (1800–2100 rpm) and welding speed (10–25 mm × min−1). Experimentation on stirwelding was performed based on selected tool pin shape between varied tool rotation and welding speed. The output responses, namely Ultimate tensile strength (UTS) and micro hardness, have been evaluated to study the effect of each tool. The microstructural characteristics of the weld samples were analyzed using optical microscope and scanning electron microscope (SEM) technique. The microstructural observation unveiled that complete fusion prevails between the parent alloys devoid of micro porosities and segregations. The re-crystallization effect resulted in the finer grains. The cylinder-shaped tool with a thread and square shaped tool rendered better strength and hardness properties of 136.6 MPa and 109.4 HV, respectively.

Kurzfassung

Aufgrund ihrer geringen Porosität, hohen spezifischen Festigkeit, Korrosionsbeständigkeit, Fließfähigkeit und guten Bearbeitbarkeit kommen Gusslegierungen in der Luft- und Raumfahrtbranche zum Einsatz. Diese Untersuchung beschäftigt sich mit dem Rührreibschweißen (Friction Stir Welding, FSW) der Gusslegierungen A356 und AA2014 bei den unterschiedlichen Prozessparametern Form des Werkzeugstifts („Pin“) (zylindrisch, zylindrisch mit Gewinde, vierkantig und konisch), Drehzahl des Werkzeugs (1.800–2.100 1/min) und Schweißgeschwindigkeit (10–25 × min−1). Die entsprechenden Rührreibschweißversuche wurden mit Werkzeugen mit ausgewählten Stiftformen bei unterschiedlichen Werkzeugdrehzahlen und Schweißgeschwindigkeiten durchgeführt. Die sich für die Zugfestigkeit (UTS) und Mikrohärte ergebenden Werte wurden zur Untersuchung des Einflusses der einzelnen Werkzeuge ausgewertet. Die Gefügeeigenschaften der Schweißproben wurden mittels Licht- und Rasterelektronenmikroskopie untersucht. Im Rahmen der Gefügeuntersuchung konnte eine vollständige Bindung der Ausgangslegierungen ohne Porosität und Seigerungen festgestellt werden. Durch den Rekristallisationseffekt bildeten sich feinere Körner. Das zylinderförmige Werkzeug mit Gewinde und das vierkantige Werkzeug lieferten mit jeweils 136,6 MPa und 109,4 HV eine bessere Festigkeit und Härte.

Keywords: Tool geometry; Cast A356 alloy; Cast A2014 alloy; Friction stir welding; UTS and Hardness; Microstructure
Schlagwörter: Werkzeuggeometrie; Gusslegierung A356; Gusslegierung AA2014; Rührreibschweißen; UTS und Härte; Gefüge

About the authors

B. S. Bindhushree

B. S. Bindhushree is currently pursuing her Ph.D. Degree in Mechanical Engineering, Dayananda Sagar University, Bengaluru, India. She completed her M. Tech in Computer Integrated Manufacturing in 2019. Her research areas of interest are stir casting, machining and friction stir welding.

P. Sevvel

P. Sevvel obtained his Ph.D. in Mechanical Engineering in 2016 and M.Tech Degree in Industrial Engineering in 2005. He has 17 years of experience. He is working as a Professor in Mechanical Engineering Department in S.A. Engineering College. 1 He has published 40 research papers in various SCI and Scopus indexed journals. His areas of research includes friction stir welding, additive manufacturing etc.

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Received: 2023-06-19
Accepted: 2024-01-10
Published Online: 2024-04-25
Published in Print: 2024-04-25

© 2024 Walter de Gruyter GmbH, Berlin/Boston, Germany

Articles in the same Issue

  1. Contents
  2. Editorial
  3. Editorial
  4. Gruson’s Fahrpanzer – Historical insights thanks to non-destructive materials science
  5. Influence of tool geometry on mechanical and microstructural characteristics of friction stir welded cast alloys
  6. Failure Analysis
  7. Enhanced susceptibility of high-strength fastener nuts to hydrogen-induced stress corrosion cracking
  8. Picture of the Month
  9. Picture of the Month
  10. News
  11. News
  12. Meeting Diary
  13. Meeting Diary
https://doi.org/10.1515/pm-2023-1055
Keywords for this article
Tool geometry; Cast A356 alloy; Cast A2014 alloy; Friction stir welding; UTS and Hardness; Microstructure

Articles in the same Issue

  1. Contents
  2. Editorial
  3. Editorial
  4. Gruson’s Fahrpanzer – Historical insights thanks to non-destructive materials science
  5. Influence of tool geometry on mechanical and microstructural characteristics of friction stir welded cast alloys
  6. Failure Analysis
  7. Enhanced susceptibility of high-strength fastener nuts to hydrogen-induced stress corrosion cracking
  8. Picture of the Month
  9. Picture of the Month
  10. News
  11. News
  12. Meeting Diary
  13. Meeting Diary
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