Characterization and Evaluation of Joint Properties of FSWed AA6061/SiC/FA Hybrid AMCs Using Different Tool Pin Profiles
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ORIGINAL ARTICLE
Characterization and Evaluation of Joint Properties of FSWed AA6061/SiC/FA Hybrid AMCs Using Different Tool Pin Profiles Sachinkumar1,3
•
S. Narendranath1 • D. Chakradhar2
Received: 5 May 2020 / Accepted: 28 June 2020 Ó The Indian Institute of Metals - IIM 2020
Abstract This work reports the characterization of AA6061/SiC/FA hybrid composites joined using friction stir welding (FSW). FSW was conducted by employing various tool pin profiles such as straight cylindrical (SC), tapered conical, straight square (SS) and cylindrical threaded. Microstructure and mechanical characteristics of joints were investigated using these tool pin profiles. Microstructure study of the weld joints was carried out through scanning electron microscopy and electron backscattered diffraction (EBSD) analysis. The results show equiaxed distribution of grains in the nugget zone. EBSD analysis indicates that the average grain size reduces to 3 lm after FSW with the presence of high-angle grain boundaries. Higher joint efficiency (85%) is obtained for joints obtained using SS tool pin compared to their counterparts, and SC tool yields minimum joint efficiency (77%). Overall 8% enhancement of the joint efficiency is achieved using SS tool pin profile. Keywords Characterization Friction stir welding Composites Tool pin profile Microstructure Microhardness
& Sachinkumar [email protected] 1
Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, Karnataka, India
2
Department of Mechanical Engineering, Indian Institute of Technology Palakkad, Palakkad, Kerala, India
3
Present Address: School of Mechanical Engineering, REVA University, Bengaluru, Karnataka, India
1 Introduction Aluminum matrix composites (AMCs) are becoming an attractive class of materials for material research community. AMCs have the advantages of specific properties of the reinforcement material and matrix aluminum [1]. Therefore, AMCs exhibit superior properties, such as higher strength, modulus, good wear resistance and low thermal coefficient of expansion, compared to base alloys [2]. Hence, AMCs are regularly finding their use in different sectors such as automotive, aerospace, marine and structural applications. But difficulties in joining of AMCs using conventional welding process and also higher cost of reinforcement particles prevent their widespread applications. Cost of the AMCs can be controlled by the use of low-cost reinforcements, namely fly ash (FA) which is available in large quantities as a by-product in thermal power plants. Obtaining the joints of AMCs using traditional joining techniques is associated with various problems such as solidification crack, porosity, chemical reactions and segregation of reinforcement particles [3]. These factors make the joining of AMCs using conventional welding processes unattractive. Such problems associated with conventional welding methods can be avoided easily by the use of a novel solid-state welding method such as friction stir welding (FSW
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