Advanced Process Possibilities in Friction Crush Welding of Aluminum, Steel, and Copper by Using an Additional Wire
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TRODUCTION
FRICTION welding is used for joining material in a solid state whereby heat is produced by a relative movement between two components under pressure. Conventional friction welding processes such as rotary, linear, and orbital friction welding are categorized according to the nature of the movement relative to their interfaces, and in accordance with their type of FLORIAN A. BESLER is with the Department of Engineering, Kempten University of Applied Sciences, 87435 Kempten, Germany and also with the Department of Mechanical and Marine Engineering, Western Norway University of Applied Sciences, Postboks 7030, 5020 Bergen, Norway and with the Department of Engineering and Applied Physics, Glyndwr University, Wrexham, LL11 2AW, UK. Contact e-mail: fl[email protected] RICHARD J. GRANT is with the Department of Mechanical and Marine Engineering, Western Norway University of Applied Sciences and also with the Department of Engineering and Applied Physics, Glyndwr University. PAUL SCHINDELE is with the Department of Engineering, Kempten University of Applied Sciences. MICHAEL J.R. STEGMU¨LLER is with the Department of Engineering, Kempten University of Applied Sciences and also with the Department of Mechanical and Marine Engineering, Western Norway University of Applied Sciences. Manuscript submitted March 29, 2017.
METALLURGICAL AND MATERIALS TRANSACTIONS B
energy supply.[1] The welded interface results in a characteristically fine-grained microstructure and the joint shows a narrow heat-affected zone.[2] The process of friction stir welding (FSW) offers an appropriate reference for the welding technique which is the subject of this article; namely, friction crush welding (FCW). Principal findings in the literature on FSW that were judged pertinent to planning an initial study of FCW are detailed in the next section, Section I–A and then a description of FCW is made in Section I–B A. Friction Stir Welding (FSW) A friction welding process for joining metals by using a non-consumable rotating tool with a specially designed pin and shoulder was conceived by Thomas and termed friction stir welding.[3] Mishra and Ma[4] presented a comprehensive analysis of FSW whereby their investigations revealed a complex material flow in the welding zone. Process parameters such as the tool geometry, the traverse speed, and the material to be joined were shown to influence the flow of material. During the process, the tool heats up the material to a certain temperature which is below the melting point and it remains in the solid phase.
Mechanical properties of friction stir-welded joints have been determined by various approaches. Research by Kallee et al.[5] revealed excellent tensile strength values of the joined workpieces which they attributed to the low heat generation. The tensile strength in the welding zone was compared with tests from different friction stir-welded aluminum alloys, including 5000, 6000, and 7000 series; they achieved similar tensile strengths to that of the parent material. Typical welding strength f
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