PARAMETRIC OPTIMIZATION IN FRICTION WELDING OF

ALUMINUM ALLOY 6351 AND STEEL 304

A PROJECT REPORT
Submitted by

PARTH NAGADIA
ARUN PATEL
RUCHIT PATEL
In fulfillment for the award of the degree
Of

Bachelor of Engineering
In

Mechanical Engineering

NARNARAYAN SHASHTRI INSTITUTE OF TECHNOLOGY

JETALPUR
GUJARAT TECHNOLOGICAL UNIVERSITY, AHMADABAD
MAY 2014

NARNARAYAN SHASTRI INSTITUTE OF TECHNOLOGY, JETALPUR

MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the project work entitled PARAMETRIC OPTIMIZATION IN
FRICTION WELDING OF ALUMINUM ALLOY AND STEEL 304 by PARH
NAGADIA [100340119014] , ARUN PATEL [100340119100], RUCHIT PATEL
[100340119029] has been carried out under my guidance in fulfillment of the Bachelor of

Engineering in Mechanical Engineering- 8th semester of Gujarat Technological

University, Ahmadabad during the academic year 2014.

INTERNAL GUIDE

H.O.D MECHANICAL

Mr. BIREN DESAI

Mr. MANISH PATEL

Dr. SARDADEVI MANDALAPU

Principal,
NSIT-JETALPUR

ii

ACKNOWLEDGMENT

A dissertation like this would not have been emerge without considerable debts to various
people for their help with specialist information, concepts for debate and valuable assistance in
the preparation and completion of this study.
First of all we are humbly expressing thanks to our respected guide Prof. Biren Desai
who has always been prepared to offer me help at any time, in spite of having busy schedule. We
heartedly thank for their inspiration, devoted attention, ingenious suggestions and unconstrained
availability which were of great help in giving this work the present form.
We are also thankful to Our Head of Department Prof. Manish Patel for his valuable
time and constant help given to me during this dissertation work.
We are also thankful to all the faculty members of Mechanical Engineering Department
and all my friends who have directly or indirectly helped me during this dissertation work.
Finally, we would like to render my heartiest thanks to my family for their great support
during this dissertation work.

Sincerely,
Nagadia Parth R.
Patel Arun B.
Patel Ruchit A.

iii

TABLE OF CONTENT
SR. NO.

CONTENT

PAGE
NO.

Chapter 1

Title

Certificate

ii

Acknowledgement

iii

Table of content

iv

List of figure

vi

List of tables

vii

Abstract

viii

Introduction

1.1Introduction

1.2 Friction welding

1.2.1 Types of friction welding

Chapter 2

1.3 Principal of friction welding

1.4 Stage of process

1.5 Taguchi method

1.6 Eight step in Taguchi methodology

1.7 Non distractive test

11

1.8 Advantage

12

1.9 Disadvantage

13

1.10 Application friction welding

13

1.10.1 Commercial

14

1.10.2 Aerospace

14

1.10.3 Hydraulic

15

1.10.4 Bimetallic

15

Literature review

16

2.1Literature review
Chapter 3

16

Design of experiments

20

3.1 Introduction

20
iv

3.2 Material Selection

21

3.3 Selection of friction welding parameters & their level

23

3.3.1 Constant process parameters during experiment

23

3.3.2 Variable parameters during experiment

23

3.3.3 Output parameter of experiment

23

3.4 Experiment set up procedure

24

3.4.1 Machine Specification

24

3.4.2 Geometry of specimen

25

3.4.3 Material properties

25

3.5 Hydraulic equipment

Chapter 4

Chapter 5

26

3.5.1 Hydraulic device

26

3.5.2 Hydraulic power pack

27

3.6 Experiment set up

27

3.7 Selection of orthogonal array

29

3.8 Tested work piece

30

3.7 Experimental result table

31

Results and validation

32

4.1 Results and discussion

32

4.2 Tensile test

33

4.3 Analysis of experiment data

34

4.4 Analysis of variance

37

4.5 Radiography test results

39

4.6 Validation

40

Conclusion

43

5.1 Conclusion

43

References

45

LIST OF FIGURE

FIG. NO
1.1

FIGURE

PAGE
NO.
4

1.2

RFW Process
Layout continuous drive friction welding

1.3

The basic steps in friction welding

1.4

Aeronautics part

13

1.5

14

1.6

Gas turbine impeller and shaft

Friction welded piston clutch and impeller casting

1.7

Bimetallic Electric Plug

15

3.1

26

3.2

Hydraulic devices
Hydraulic Power Pack

3.3

Schematic Diagram Experiment Set Up

28

3.4

Experiment set up

29

3.5

Before tested part after tested part

31

4.1

Universal Testing machine

34

4.2

Graphical analysis tensile strength with different parameter

39

14

27

vi

LIST OF TABLES

TABLE NO.

PARTICULAR

PAGE
NO

3.1

Friction stir welding parameters and their levels

24

3.2

chemical properties of material used in present study

25

3.3

Mechanical properties of material used in present study

25

3.4

Orthogonal Array [L9]

30

3.5

Experiment result table with different parameter

31

4.1

S/N Ratio of experiment Reading

36

4.2

Optimum Parameter

37

4.3

NDT test report

40

4.4

Chemical properties of AA 6082 and AA 6351 with steel 304

40

4.5

Obtained tensile strength results AA 6082 and steel 304

41

4.6

Obtained tensile strength results AA 6351 and steel 304

41

vii

PARAMETRIC OPTIMIZATION IN FRICTION

WELDING OF ALUMINUM ALLOY 6351 AND
STEEL 304
Submitted By

NAGADIA PARTH RANJITBHAI

PATEL ARUN BHARATBHAI
PATEL RUCHIT ASHWINBHAI

Supervised By
Prof. BIREN DESAI
Narnarayan Shastri Institute of Technology, Jetalpur

ABSTRACT

In friction welding, the joints are formed in the solid state by utilizing the heat generated
by friction. The objectives of this study are obtaining friction weld element of Aluminum
6351, steel 304 and optimizing the friction welding parameters in order to establish the
weld quality. This paper discusses use Taguchi experiment design technique for
maximizing tensile strength of friction welding Al (6351) and steel 304. An orthogonal
array of L9 was; Using ANOVA and signal to noise ratio of robust design, effect of
tensile strength of friction welding process parameter (Rotational speed, forging force,
time) is evaluated and optimum welding condition for maximizing tensile strength is
determined and also NDT (Radiography test) testing to measure continuity of weld joint.

Keywords

Friction Welding, Stainless Steel,

Optimization by Taguchi methodology

viii

Aluminum,

Tensile Strength,

CHAPTER 1

INTRODUCTION

1
INTRODUCTION
1.1 Introduction
This thesis is a contribution to research work with the final ambition of friction
welding steel to aluminum material. The friction welding process was selected for joining
steel to an aluminum material after a literature study showed that this is a possible
feasible technology. The goal of this thesis is to help in the assembly of this machine and
to gain some experience in welding this particular material combination because not a lot
of experimental research can be found on this topic. The principles of welding steel to
aluminum material can also be applied to other dissimilar material combinations.[2]
Energy savings and environmental preservation are important issues for us to
resolve. Since reducing the weight of vehicles is one of the efficient measures, the use of
the combination of steel and aluminum alloy has been increasing in fabricating vehicles.
Under this situation, many trials to weld steel to aluminum alloy have been conducted.
However, present structures made of stainless steels cannot be entirely replaced with
aluminum alloy structures, taking into account strength, weld ability, and economics,
although it is possible to replace part of a structure with aluminum alloy components.[2]

1.2 Friction welding

Friction welding is a solid-state joining process that can produce high-quality
welds between two components with either similar or dissimilar chemical compositions.
The friction welding components are forced to rub against each other, thereby generating
heat at the interface. This softens the material on either side of the rubbing interface. The
softened materials starts to flow together to initiate a weld. Once enough heat has been
generated, the rubbing action is terminated and the contact pressure is maintained or
increased for a period of time, to promote the solid-phase bond. Therefore, the friction
1

CHAPTER 1

INTRODUCTION

welding process requires a machine which is designed to convert mechanical energy into
heat at the joint interface using relative movement between work pieces. [1-5]
Friction welding is the welding process in which the heat required for welding is
obtained by friction between the ends of the two parts to be joined .One of the parts to be
joined is rotated at a high speed near and the other part is axially aligned with the second
one and pressed tightly against it. The friction between the two parts raises the
temperature of both the ends. Then the rotation of the part is stopped abruptly and the
pressure on the fixed part is increased so that the joining takes place. This is also called as
Friction Welding.
As it is known, friction welding is used extensively in various industries
nowadays. Heat in friction welding is generated by conversion of mechanical energy into
thermal energy at the interface of the work pieces during rotation under pressure. Various
ferrous and non-ferrous alloys, which have circular or non-circular cross sections, having
different thermal and mechanical properties can easily are joined by the friction welding
method. Friction welding is classified as a solid-state welding process where metallic
bonding is produced at temperatures lower than the melting point of the base metals.
Friction time, friction pressure, forging time, forging pressure and rotation speed are the
most interesting parameters in the friction welding method [3]

1.2.1 Types of friction welding

Linear Friction Welding (LFT)
Linear Friction Welding is one type of friction welding that is mainly used for the
aerospace industry as it allows the welder to weld different materials; it is used for
repairing of machinery parts and to build state of the art gas turbine parts that are difficult
to build using conventional welding methods. Basically, it involves non-melting plastic
deformation process to produce high integrity weld parts with lesser or no prior surface
preparation.
In linear friction welding as the relative motion between the work pieces is linear. It is
used in joining turbine blades to the rotor in the aerospace industry. Now-a-days
2

CHAPTER 1

INTRODUCTION

researchers are working on low-price linear friction welding machines for automotive
industry where it may be used for manufacturing brake discs, wheel rims piston heads
etc.
In LFW process the parts to be welded are forced to come in direct contact of
each other and then they are subjected to an overturned motion .This results in frictional
heating of work pieces at the weld plane, thereby raising its temperature near to its
Melting point. As time passes this thermo-plastic layer is extruded at the periphery of the
weld-layer as undulated sheets of metal termed as flash. The formation of flash conforms
the fact that any interfacial has been thrown out during the friction between the parts. The
heat affected zone (HAZ) in LFW is small because the joining of parts takes place at a
faster rate and the direct heat input to the weld-pool is just enough to create a small HAZ.
So with proper selection of material and weld parameters, the material deformation at the
weld surface can be controlled.[7]
Till today a lot of research has been done on LFW. It has been commonly
accepted that friction welding can be differentiated into 3 stages such as
(i) A dry friction stage, followed by
(ii)

An increased rigorous contact, and

(iii) Some kind of steady phase once the required high weld temperature is
acquired. It is not known how the surface dirt is thrown out specifically from the
mid-point of the weld surface.
The problems that lie with LFE are the tribology of the job, heat flow in the weld
pool and more specifically the representation of the thermo-plastic material flow during
steady state LFW. It is a necessity that these facts have to be systematically addressed so
that an appropriate material extrusion model can be formulated accurately. This will
ensure in reduction of computational cost found in doing FEA of the processes be kept
within acceptable limits.

Spin Welding
This is mainly used for welding polymers. It includes four stages such as
(i) The dry friction stage
(ii) The transition stage
3

CHAPTER 1

INTRODUCTION

(iii) The steady state stage

(iv) The cool down phase.
In the solid friction stage, frictional heat is generated due to the interaction between the
work pieces between the two surfaces. This stimulates the polymer material to get heated
up until the melting point is attained. The generation of heat depends on the applied
tangential velocity and the pressure.
In the transition stage, a thin molten polymer layer gets formed which appears as
a result of the frictional heat generation. A thin molten layer exists at the starting and
accordingly the shear rate and viscous heating contributions are large. As the process
goes on this layer grows thicker and temperature raises to that required for welding.
The steady stage involves the outward melting of the polymer and it achieves a
steady rate. In this stage the thickness of the layer remains constant. This stage is kept
until a certain "melt down depth" has been attained at which the rotation is stopped. At
the final stage the polymer is allowed to cool and during cooling it solidifies to form a
strong joint.[6]

Rotary Friction Welding (RFW)

In RFW, one work piece is rotated against the other. It is the most commonly used
friction welding process in automobile industry. The process has been used to
manufacture suspension rods, steering columns, gear box forks and drive shafts and
engine valves, in which there is requirement of welding of unalike materials of valve
stem and head.

Fig. 1.1 RFW Process

CHAPTER 1

INTRODUCTION

Inertia Friction Welding

In this friction welding, the energy required to make the weld is harnessed from
the rotational KE stored in a fly wheel of the welding set up.
In Inertia Friction Welding, one part is connected to a flywheel and the other is
constrained from rotating. The flywheel is accelerated to a specific rotational speed to
store the required energy. Then the driving motor is withdrawn and the work pieces are
forced together to interact directly. This drives the surfaces to rub against each other
under pressure. The kinetic energy stored in the rotating flywheel forces the part attached
to t to rotate and this rotation is opposed by the other constrained part which results in
generation of heat. Due to the opposition by the constrained work piece the fly wheel get
slowed down and its KE gets converted into heat. An increment axial force is applied
before rotation stops. The axial force is kept for a specific time even after rotation stops.

Friction Stud Welding

It was developed by the USA Navy in 1998 and was first commercially performed
at a depth of 1300 feet and involved the friction welding of anode continuity tails to riser
base piles using a work-class ROV. The instrument used for the welding process was a
Circle Technologies HMS 3000, which is hydraulically-driven, electronically-controlled,
and rated to a depth of 3,000 feet (910m). Based on this concept, the Naval Sea Systems
Command (NAVSEA) initiated another program to evaluate underwater friction stud
welding for use in submarine rescue.
Oceaneering developed the application for commercial offshore submarine repairs
at the same time when Navy tried to use the method to for underwater friction stud
welding for rescue missions in case of underwater accidents in sea. But there was a little
public information on the mechanical properties of underwater friction stud welding. The
usability of this process for any offshore repairing without a complete knowledge of
mechanical, corrosion, and fatigue would not be acceptable.

CHAPTER 1

INTRODUCTION

Friction Stir Welding

Friction Stir Welding (FSW) is a recently developed friction welding process
which was developed at The Welding Institute (TWI), Cambridge, UK [19].This method
uses a rotating non-consumable welding tool.
This technique uses a non- consumable rotating tool to create frictional heat and
distortion at the welding position, thereby upsetting the development of a joint, while the
material is in the solid state. The main benefits of FSW, being a solid-state procedure, are
low alteration, absenteeism of melt-related flaws and great joint strong point, even in
those alloys that are considered non-joinable by conventional practices (e.g.,5xxx and
6xxx series aluminum alloys). In addition, friction stir welded joints are regarded as the
absence of filler-induced glitches or defects, since the method necessitates no filler. Also
the hydrogen damage that occurs during welding of steel and other iron alloys has to be
avoided by decreasing the hydrogen contents of the friction stir welded joints.[7]

1.3 PRINCIPLE OF FRICTION WELDING:

Friction welding is carried out by translating or rotating one component
comparative to another along a mutual boundary, whereas smearing a compressive force
through the joint. The frictional heat gets spawned at the boundary softens both
components and when they got altered the border material gets extruded out of the ends
of the combined so that fresh material from each module is gone along the new interface.
The relative cue is then stopped, and a advanced closing compressive power is applied
earlier to the joint is permitted to cool. The main aspect of friction welding is that no
liquefied solid is generated as the weld gets created in the solid state itself.[7]
The definition of friction welding in the American Welding Society (AWS) C6.1-89
standard is as follows: Friction welding is a solid-state joining process that produces
coalescence of materials under compressive force contact of work pieces rotating or
moving relative to one another to produce heat and plastically displace material from the
faying surfaces. Under normal conditions, the faying surfaces do not melt. Filler metal,
flux, and shielding gas are not required with this process. [7]
6

CHAPTER 1

INTRODUCTION

Fig: 1.2 Layout continuous drive friction welding [3]

The principle of this method is the changing of kinetic energy (it may be
rotational or translational) energy into heat energy through friction. One piece is obsessed
and revolved about its axis while the other part to be joined to it is engrossed and is not
revolved but can be relocated axially to create interaction with the spinning component.
When fusion temperature is reached, then gyration is clogged and forging pressure is
smeared. Heat is produced due to friction and is focused and contained at the edge, grain
structure is polished by scorching exertion. Then the joint gets formed but there is no
melting of material.

1.4 Stages of the process:

Generally, friction welding involves three basic stages. During the first stage,
sometimes called the heat-up stage, the two components, which have a relative motion
with respect to each other, are brought into contact and an axial compressive force is
applied. Heat generated by friction increases the temperature of the components at the
rubbing interface, which decreases the materials flow stress. Eventually, the material is
unable to withstand the applied axial compressive force and plastically flows outwards to
form the flash, carrying oxides and contaminations. Flash formation takes place during
this stage, which is denoted as the burn-off stage. Finally, during the forging stage, the
welding process is completed by stopping the relative motion and applying a high
compressive force. [1]
Show in figure 1.3 First one work piece is rotated and other is held stationary as
shown in the Figure A. When the appropriate rotational speed is reached, the two work
7

CHAPTER 1

INTRODUCTION

pieces are brought together the axial force is applied, as shown in the Figure B. Rubbing
at the interface heats the work piece locally and upsetting starts, as shown in the Figure
C. Finally, the rotation of one of the work pieces stops and the upsetting is completed, as
shown in the Figure D.

Figure 1.3 The basic steps in friction welding [2]

The weld produced is characterized by the narrow heat affected zone, the
presence of plastically deformed material around the weld (flash), and the absence of
fusion zone.[2]

1.5 Taguchi method

After the Second World War, the allied forces found that the quality of the
Japanese telephone system was extremely poor and totally unsuitable for long-term
communication purposes. To improve the system the allied command recommended
establishing research facilities in order to develop a state-of-the-art communication
system. The Japanese founded the Electrical Communication Laboratories (ECL) with
Dr. Genichi Taguchi in charge of improving the R&D productivity and enhancing
product quality. He observed that a great deal of time and money was expended on
engineering experimentation and testing. Little emphasis was given to the process of
creative brainstorming to minimize the expenditure of resources. He noticed that poor
quality cannot be improved by the process of inspection, screening and salvaging. No
8

CHAPTER 1

INTRODUCTION

amount of inspection can put quality back into the product. Therefore, he believed that
quality concepts should be based upon, and developed around, the philosophy of
prevention.[10]
Taguchi started to develop new methods to optimize the process of engineering
experimentation. He believed that the best way to improve quality was to design and
build it into the product. He developed the techniques which are now known as Taguchi
Methods. His main contribution lies not in the mathematical formulation of the design of
experiments, but rather in the accompanying philosophy. His concepts produced a unique
and powerful quality improvement technique that differs from traditional practices. He
developed manufacturing systems that were robust or insensitive to daily and seasonal
variations of environment, machine wear and other external factors. [10]
To achieve desirable product quality by design, Taguchi suggests a three-stage
process: system design, parameter design, and tolerance design. System design is the
conceptualization and synthesis of a product or process to be used. The system design
stage is where new ideas, concepts and knowledge in the areas of science and technology
are utilized by the design team to determine the right combination of materials, parts,
processes and design factors that will satisfy functional and economical specifications. To
achieve an increase in quality at this level requires innovation, and therefore
improvements are not always made. In parameter design the system variables are
experimentally analyzed to determine how the product or process reacts to uncontrollable
noise in the system; parameter design is the main thrust of Taguchis approach.
Parameter design is related to finding the appropriate design factor levels to make the
system less sensitive to variations in uncontrollable noise factors, i.e., to make the system
robust. In this way the product performs better, reducing the loss to the customer.

1.6 Eight-steps in Taguchi methodology

Step1: Identify the main function, side effects, and failure mode
Step2: Identify the noise factors, testing conditions, and quality characteristics
Step3: Identify the objective function to be optimized
Step4: Identify the control factors and their levels
9

CHAPTER 1

INTRODUCTION

Step5: Select the orthogonal array matrix experiment

Step6: Conduct the matrix experiment
Step7: Analyze the data; predict the optimum levels and performance
Step8: Perform the verification experiment and plan the future action[10]
The final step in Taguchis robust design approach is tolerance design; tolerance
design occurs when the tolerances for the products or process are established to
minimize the sum of the manufacturing and lifetime costs of the product or process. In the
tolerance design stage, tolerances of factors that have the largest influence on variation
are adjusted only if after the parameter design stage, the target values of quality have not
yet been achieved. Most engineers tend to associate quality with better tolerances, but
tightening the tolerances increases the cost of the product or process because it requires
better materials, components, or machinery to achieve the tighter tolerances as we
discussed in earlier chapters.
In contrast, taguchi approach is based on executing one large comprehensive
experiment. This approach is not based on the principal of sequential experiment. More
specifically a comprehensive experiment is planned assuming that the comprehensive
experiment is planned assuming that the objective and all the data analyzed by analysis of
variance in term of measure devised by Taguchi know as signal to-ratios. Finally,
based on this calculation, taguchi shows how to choose the optimum condition. [6]
The steps included in the Taguchi parameter design are: selecting the proper
orthogonal array (OA) according to the numbers of controllable factors (parameters);
running experiments based on the OA; analyzing data; identifying the optimum
condition; and conducting confirmation runs with the optimal levels of all the parameters.
Basically, the degrees of freedom for the orthogonal array should be greater than or at
least equal to those for the process parameters. In this study, an L9 orthogonal array was
used. This array has twenty six degrees of freedom and it can handle three-level process
parameters. Each FS welding parameter is assigned to a column and twenty seven
welding parameter combinations are available.

10

CHAPTER 1

INTRODUCTION

The main effects indicate the general trend of influence of each parameter.
Knowledge of the contribution of individual parameters is the key to deciding the nature
of the control to be established on a production process. Analysis of variance (ANOVA)
is the statistical treatment most commonly applied to the results of the experiments to
determine the percentage contribution of each parameter against a stated level of
confidence. Taguchi suggests two different routes for carrying out the complete analysis.
In the standard approach the results of a single run or the average of repetitive runs are
processed through the main effect and ANOVA (raw data analysis). The second
approach, which Taguchi strongly recommends for multiple runs, is to use the signal-tonoise (S/N) ratio for the same steps in the analysis.[9]
The preferred parameter settings are then determined through analysis of the
signal-to-noise (SN) ratio where factor levels that maximize the appropriate SN ratio
are optimal. There are three standard types of SN ratios depending on the desired
performance response.
Smaller the better (for making the system response as small as possible):

SNS= -10 log

1
4

2
=0

Larger the better (for making the system response as large as possible):

SNL= -10 log

1
4

=0 2

1.7 Non destructive test

Nondestructive testing (NDT) is the process of inspecting, testing, or evaluating
materials, components or assemblies for discontinuities, or differences in characteristics
without destroying the serviceability of the part or system. In other words, when the
inspection or test is completed the part can still be used. In contrast to NDT, other tests
are destructive in nature and are therefore done on a limited number of samples ("lot
sampling"), rather than on the materials, components or assemblies actually being put
into service.
These destructive tests are often used to determine the physical properties of
materials such as impact resistance, ductility, yield and ultimate tensile strength, fracture
11

CHAPTER 1

INTRODUCTION

toughness and fatigue strength, but discontinuities and differences in material

characteristics are more effectively found by NDT. Today modern nondestructive tests
are used in manufacturing, fabrication and in service inspections to ensure product
integrity and reliability, to control manufacturing processes, lower production costs and
to maintain a uniform quality level. During construction, NDT is used to ensure the
quality of materials and joining processes during the fabrication and erection phases, and
in-service NDT inspections are used to ensure that the products in use continue to have
the integrity necessary to ensure their usefulness and the safety of the public.

1.8 Advantages
Friction welding is cost-effective since it badges joining together dissimilar
materials, one of them may be cheap and its quality controller cost may be minimal with
an assurance of high strength welds. Furthermore, the weld cycle is very short, so that
output is very eye-catching. Friction welding process may fit for mass manufacture.
The friction welding route is right for non-homogeneous joints linking things
having quite altered mechanical, chemical and thermal properties. The procedure is
appropriate for automation and adoptable for robotic application. Other advantages are:
- Material and machining charge savings is more
- Full cross section gets bounded perfectly
- High manufacture rates
- Weld heat affected zone (HAZ) has a reasonable grain hot-worked construction
-

Like and unlike materials can be welded with no extra fluxes or filler metals

- Superb mechanical properties are proven by fatigue, tensile, bend experiments

- No hazardous gas is produced
- No sponginess
- No scatter
- No need of recruiting certified welders for performing FSW
-

It is more energy effective than other welding skills

- FSW joint strong point is similar or even greater than that of parent material
-

It can weld cheap, less heavy or cylindrical material to expensive material.

12

CHAPTER 1

INTRODUCTION

1.9 Disadvantages
Friction welding has some disadvantages such as friction welding of all structure
is not practicable, a machine of adequate power is required and short run of the welding
process may not be economical.
Other disadvantages are cost of instruments required which must be right for the
proposed joins, the cost of the tools to be used and the set up cost. These costs per weld
may become very high for welding dissimilar materials such as Titanium, Magnesium
etc. Close-fitting among parts and maintaining close concentricity that are required for
FSW may become difficult in some cases. Likewise there may be rise in total cost when
finishing procedures are required.
1.10 Applications of Friction Welding
As time passes friction welding has found many applications in Commercial,
Aerospace, Hydraulic, Automotive industries etc

1.10.1 Commercial
Inertia Friction Welding is mainly used for commercial purpose because the weld
is skillful rapidly and with smallest clean-up. Since the weld has high strength, it delivers
a solider quantity than customary welds. Tool additions, tool spaces, baseball bats, air
cylinders, ammunitions, fasteners, oil cylinders and water tube fittings, bicycle parts,
medical equipment, marine equipment, electrical tools, photographic and sound apparatus
are made using inertia friction welding.

Figure 1.4 Aeronautics part

13

CHAPTER 1

INTRODUCTION

1.10.2 Aerospace
Inertia Friction welding and friction stir welding are mainly used in aerospace
industry. These are used to manufacture aero-plane parts such as gas turbine wheels and
shafts, pressure containers, landing stage gear struts, ball screw assemblies, actuator
modules and gear assemblages. Many friction welded parts have been cast-off in
satellites, space shuttles etc.

Figure 1.5 Gas turbine impeller and shaft

1.10.3 Hydraulic:
Hydraulic cylinders and valves are manufactured and repaired through inertia
welding. The cylinders are entirely machined and the caps are welded on later for cost
reductions and nominal inventory necessities. For manufacturing irregular profiles, the
cylinder is welded to a bigger part of material to decrease cost and machine time. This
method is also used for piston manufacturing.

Figure 1.6 Friction welded piston clutch and impeller casting

14

CHAPTER 1

INTRODUCTION

1.10.4 Bimetallic application

Aerospace and aircraft components, cutting tools, agriculture machinery,
automotive parts, oil filled cylinders, waste canisters, military equipment, spindle blanks
and bimetallic components used in electrical machines are manufactured using different
friction welding techniques.

Figure 1.7 Bimetallic Electric Plug

15

CHAPTER 2

LITERATURE REVIEW

2
LITERATURE REVIEW
2.1 Literature Review
1.

It is a fact that the essential force to originate sliding a material is better than that to
continue motion so the coefficient of static friction becomes greater than coefficient
of dynamic friction. It is detected that the choice of standards of frictional forces
varies by orders of scale dependent on the span of the tenders, macroscopic or
microscopic.
Mathematically,

Friction force = coefficient of friction X normal weight

2.

A.R.D. Industries manufactures friction welded parts and has performed sub-contract
friction welding of costumer goods for a large number of companies that include
agricultural, automotive, electrical, forestry, mining, transportation and other
correlated industries. A.R.D. Industries is one of the biggest frictions welding subcontract manufacturer in Canada.

3.

Whitley Eder Paduan Alves* Institute of Aeronautics and Space So Jos dos
Campos Brazil The purpose of this work was to assess the development of solid
state joints of dissimilar material AA1050 aluminum and AISI 304 stainless steel,
which can be used in pipes of tanks of liquid propellants and other components of the
Satellite Launch Vehicle. Tests were conducted with different welding process
parameters and the results were analyzed by means of tensile tests, Vickers micro
hardness, metallographic tests and SEM-EDX. The strength of the joints varied with
increasing friction time and the use of different pressure values.[14]

4.

Emel Taban a,*, Jerry E. Gould b, John C. Lippold. Dissimilar friction welding of
6061-T6 aluminum and AISI 1018 steel. Specifically, the introduction of aluminum
alloy parts into a steel car body requires the development of reliable, efficient and
16

CHAPTER 2

LITERATURE REVIEW

economic joining processes. Since aluminum and steel demonstrate different

physical, mechanical and metallurgical properties, identification of proper welding
processes and practices can be problematic. In this work, inertia friction welding has
been used to create joints between a 6061-T6 aluminum alloy and a AISI 1018 steel
using various parameters. Optimum speed rpm related to bending strength (Mpa).[12]

5.

Calvin Blignault study about Friction welding established empirical formula that
determines the relationship between welding speed, material thickness, tool
geometry and material type. The following formula indicates the relationship
between these parameters.[18]

V = feed rate mm/min

= material facto
= tool factor
t = material thickness (mm)

6.

J. Adamowski et al. analyzed the mechanical properties and micro structural

variations in Friction Stir Welds in the AA 6082-T6 with varying process
parameters. Tensile test of the welds was done and relation among the process
parameter was judged. Microstructure of the weld interface was observed under
optical microscope. Also micro hardness of the resulting joint was measured. It was
observed that test welds show resistance to increment of welding speed, Hardness
reduction was observed in weld nugget and heat affected zone (HAZ). The reason for
this occurrence was the kinetic and thermal asymmetry of the FSW process.. The
hardness was inferior to that of fusion welding. Tunnel defects were found in the
nugget zone.[15]

17

CHAPTER 2

7.

LITERATURE REVIEW

M.Vural scrutinized the friction stir welding competency of the EN AW 2024-0 and
EN AW 5754-H22 Al alloys. These two Aluminum alloys are extensively used in the
industry. The experiment presented that the hardness value of EN AW 2024-0 at the
weld area is increased about 10-40 Hv. This may be the result of recrystallization and
compact grain structure formation. But hardness of EN AW 5754-H22 got decreased
due recrystallization and loose grain structure formation. Welding performance of
EN AW 2024-0 is 96.6 and for EN AW 5754-H22 it is 57%. Welding performance
of dissimilar Aluminum alloys EN AW 2024-0 and EN AW 5754-H22 is reached a
value of 66.39%. Analysis of Welding zone using scanning electron microscope
showed no change in the microstructure in the welding zone. Hardness distribution at
the weld zones didnt show any significant change in hardness.

8.

Yong-Jai Kwon et al. investigated the friction stir welding between 5052 aluminum
alloy plates with a thickness of 2 mm. The tool rotation speeds were ranging from
500 to 3000 rpm under a constant traverse speed of 100 mm/min. Welded joints were
obtained at tool rotation speed 1 000, 2000 and 3000 rpm. At 500, 1000, and 2 000
rpm onion ring structure was clearly observed in the friction-stir-welded zone (SZ).
The effect of tool rotation speed on the onion rings was observed. Gain size in the SZ
is smaller than that in the base metal and is decreased with a decrease of the tool
rotation speed. The study showed that the strength, tensile strength of the joint is
more than that of the parent metal. The investigation also demonstrated that the joint
is less ductile than the parent alloy.[20]

9.

Yeung, M.N. Ahmad Fauzi,M.B. Uday, H. Zuhailawati, A.B. Ismail are investigated
Microstructure and mechanical properties of alumina-6061 aluminum alloy joined by
friction welding alumina-6061 aluminum alloy joints were welded successfully by
friction welding. Some interesting developments of microstructure and properties
were observed in the welding area. The HAZ is very narrow, if not non-existent, in
the case of 1250 rpm and the bending strength values obtained were greater in joint
using rotational speed of 2500 rpm than with 1250 rpm. The use of higher rotational
speed with constant friction time and pressure increases the bending strength of
18

CHAPTER 2

LITERATURE REVIEW

friction welded as a result of heat input, high plastic deformation and shearing of
grains at the interface.[16]

10. Wang, SHUBHAVARDHAN R.N & SURENDRAN S in investigated friction

welding to join stainless steel 304 and aluminum 6082 materials via continuous drive
friction welding process and study about austenitic stainless steel (AISI 304) and
aluminum materials were welded successfully. The welding process was investigated
by tensile testing, impact testing, Vickers micro hardness testing, fatigue testing,
micro structural observation, and EDS measurements with the following results. The
weld joint with optimum upset pressure and upset time absorbed valuable amount of
energy representing the complete bonding and good weld strength at the interface,
compared with the other two, lesser upset pressure and upset time, and higher upset
pressure and upset time weld joint specimens.[2]

11. Friction stir welding of different materials was done by D.Muruganandam for four
different tool rotation speeds namely 600, 800, 1000 and1200 rpm. Radiology was
done to study the defects in the weld joint. The analysis indicated that defect
concentration was maximum for the 600 rpm tool rotation. It was a little reduced for
800 rpm and even lesser for the 1000 rpm speed rotation. Least defects were found at
the highest rpm (1200). [23]
12. Shyam Kumar Karna1, Dr. Ran Vijay Singh2, Dr. Rajeshwar Sahai was carried out
Application of Taguchi Method in Indian Industry and he investigate Taguchi
Parameter Design is a powerful and efficient method for optimizing the process,
quality and performance output of manufacturing processes, thus a powerful tool for
meeting this challenge. Off-line quality control is considered to be an effective
approach to improve product quality at a relatively low cost. [22]

19

CHAPTER 3

DESIGN OF EXPERIMENT

3
DESIGN OF EXPERIMENT
3.1 Introduction
Design of Experiment (DOE) is a powerful technique used for exploring new
processes, gaining increased knowledge of existing process and optimizing these
processes for achieving world class performance. DOE is an experimental strategy in
which effects of multiple factors are studied simultaneously by running tests at various
levels of the factors. What levels should we take, how to combine them, and how many
experiments should we run, are subjects of discussions in DOE. The Design of
experiment is used to develop a layout of the different conditions to be studied. An
experimental design must satisfy two objectives: first, the number of trials must be
determined; second, the conditions for each trial must be specified. Before designing an
experiment, the knowledge of the product/process under investigation is of prime
importance for identifying the factors likely to influence the outcome.
Design of experiments, DOE, is used in many industrial sectors, for instance, in
the Development and optimization of manufacturing processes. Typical examples are the
Production of wafers in the electronics industry, the manufacturing of engines in the car
industry, and the synthesis of compounds in the pharmaceutical industry. Another main
type of DOE-application is the optimization of analytical instruments. Many applications
are found in the scientific literature describing the optimization of spectrophotometers
and Chromatographic equipment. Usually, however, an experimenter does not jump
directly into an optimization problem rather initial screening experimental designs are
used in order to locate the most fruitful part of the experimental region in question. Other
main types of application where DOE is useful is robustness testing and mixture design.
The key feature of the latter application type is that all factors sum to 100%. Areas where
DOE is used are in industrial research, development and production, Optimization of
20

CHAPTER 3

DESIGN OF EXPERIMENT

manufacturing processes, Optimization of analytical instruments screening and

identification of important factors robustness testing of methods Robustness testing of
products Formulation experiments. [16]
In this investigation of friction welding, dissimilar material Aluminum alloy 6351
and stainless steel 304 is fixed to a fixture for the experiment and the fixture in turn is
held with the help of chuck of a center lathe and the tool is attached to the drill chalk with
hydraulic power pack system.

3.2 Material selection:

Genetic Dissimilar metal joining offers the potential to utilize the advantages of different
materials often providing unique solutions to engineering requirements. The main reasons
for dissimilar joining are due to the combination of good mechanical properties of one
material and either low specific weight or good corrosion resistance or good electrical
properties of second material. Consequently, joining processes for dissimilar materials
have received considerable attention in the recent years.
The need to expand the use of lightweight structures in the automotive industry
has increase interest in the use of both aluminum and magnesium as structural materials.
However, the cost of aluminum compared to steel restricts its application for automobile
parts. [1]
Solid-state bonding of aluminum alloys to steels has been investigated by many
authors for more than 50 years, probably because these are structural materials most
widely used in a variety of industries, and possess mechanical and chemical properties
quite different from each other. Recently, it attracts even more attention to meet the
demands for weight reduction and enhancement of the energy efficiency of vehicles from
an ecological point of view.
Aluminum Alloy AA6351: Aluminum alloy AA6351 is a medium Strength alloy
with excellent corrosion Resistance. It has the highest strength of the 64430 series alloys.
Alloy AA6351 is known as a structural alloy. In plate form, AA6351 is the alloy most
commonly used for machining.The addition of a large amount of manganese controls the

21

CHAPTER 3

DESIGN OF EXPERIMENT

Grain structure which in turn results in a stronger alloy. Alloy AA6351 machines well
and produce tight coils of swarf when chip breakers are used.
However, joining of aluminum to steel is not easy for the following reasons:

Much higher melting point of steel compared to aluminum,

Difference of the thermal expansion coefficients between steel and aluminum, the
very tenacious superficial oxide film on aluminum alloys, which interferes with
the Achievement of a metal-to-metal contact at the interface,

Formation of brittle intermetallic compounds (IMC). [3]

The most serious problem is the formation of brittle intermetallic compounds

resulting from the reaction of Al with Fe. In particular, fusion welding involves
the formation of large amounts of intermetallic compounds in the weld metal
because steel and aluminum are mixed in the liquid state and thus has been
considered to be unsuitable for fusion welding. [3]
In contrast, formation of the intermetallic compound in solid-state welding can be

controlled by selecting suitable bonding parameters, since the creation of the IMC is
controlled by diffusion of reacting elements in the solid state. For this, many
investigations have been reported of solid-state bonding of aluminum alloy to steel.
Friction welding is a process most widely used for joining of dissimilar metals because of
its high productivity and reliability of the joint performance, in addition to the
controllability of the formation of the IMC layer.[3]
However, several authors have reported cases were friction welds of aluminum to
steel fractured at the interface showing lower strength than the base metal, even when the
IMC layer was less than 1 m thick. In this regard, no clear explanation has been given
for the controlling factor of the joint strength. In particular, aluminum alloys with a high
Mg content have a lower joint efficiency and a narrower Pieter Rombaut 18 Academic
Year 2010-2011 parameter window to obtain a high joint efficiency. Magnesium is
therefore a very important element added to a variety of industrial Al alloys. [3].

22

CHAPTER 3

DESIGN OF EXPERIMENT

3.3 Selection of friction welding parameters and their levels

The main variables in direct drive friction welding are the rotational speed, the
axial forces and the welding time. These variables determine the amount of energy
introduced in the weld zone and the rate of heat generation at the interface. It is to be
noted that the heat generation rate is not constant across the weld interface and that it also
varies during the different stages of the welding cycle.

3.3.1 Constant process parameters during experiment

Work-piece material- aluminum 6351 and steel 304

Diameter of work piece- 16 mm

3.3.2 Variables parameter during experiments:

Rotation speed
Forging pressure (MPa)
Friction time

Rotation Speed:
Fiction welding is a process in which rotating speed due to heat for welding is produced
by direct conversion of mechanical energy to thermal energy at the interface of the work
pieces.

Forging pressure
American Welding Society (AWS) as a solid state welding process that produces a weld
under compressive force (forging pressure) contact of work pieces rotating or moving
relative to one another to produce heat and plastically displays material from the faying
surfaces. The joint strength increased and then decreased after reaching a maximum
value, with increasing upset pressure and upset time.

Friction time:
A longer upset time caused the excess piercing into a smooth aluminum material forming
an intermetallic layer. However, some of the welds showed poor strength depending on
some accumulation of alloying elements at the interface, which are the result of a
23

CHAPTER 3

DESIGN OF EXPERIMENT

temperature rise and the existence of intermetallic layers such as FeAl. The steps
included in the Taguchi parameter design are: selecting the proper orthogonal array (OA)
according to the numbers of controllable factors (parameters); running experiments based
on the OA; analyzing data; identifying the optimum condition; and conducting
confirmation runs with the optimal levels of all the parameters as per review paper

[12].

Table 3.1 Friction stir welding parameters and their levels

Parameter
Rotational speed (rpm)
Forging pressure(MPa)
Friction time (sec)

Level

Factor
1
965
200
8

A
B
C

2
1200
210
9

3
1500
230
10

Show the table 1 In order to investigate the effect of friction welding process
parameters, most researchers follow the experimental techniques wherein three parameter
has been varied over a period of time keeping other parameters constant. This kind of
conventional parameter based design of experiment approach is time consuming and
consumes enormous amount of resources.

3.3.3 Output parameters of experiments:

Tensile strength

Non Destructive Testing(radiography)

3.4 Experimental set-up and procedure.

3.4.1 Machine Specification:
All gear lathe machine and machine specification below: All critical components like
shafts, gears, pins, lead screw are made out EN-8/EN-9 alloy steel; force lubrication
system in head stock; rigid and box section type bed; accuracy conforms to Indian
standard IS: 1878 (Part-1) 1993
Centre height 175 mm

Admit between centre 650 mm, 1000 mm

Swing over bed 350 mm

24

CHAPTER 3

DESIGN OF EXPERIMENT

Over cross side 215 mm

In gap 540 mm

Speed 965,1200,1500 rpm

Motor 1440 RPM, 50 cycles, 3-phase, AC power, 2.25 kW/3 HP

3.4.2 Geometry of the Specimens:

Specimens were machined from materials according to the required

dimensions[2].Specimen dimensions are as follows: AISI 304 Stainless steel and
AA 6351 aluminum alloy Bars of length 100mm, Diameter 16 mm and steel 304
length 76mm and 16 with total quantity 27 piece.

3.4.3 Material properties:

For present study reference ASTM (American standard testing of material) to mechanical
and chemical properties take below:
Table 3.2 chemical properties of material used in present study
AA
6351

Si
Zn
Mg Mn Fe
Cu
Ti
Sn
Ni
0.907 0.89 0.586 0.65 0.65 0.086 0.015 0.003 0.002

Steel 304

Si
0.38

S
0.024

P
0.036

Mn
1.67

C
0.65

Al
balance

Cr
0.054

Ni
18.2

Table 3.3 Mechanical properties of material used in present study

Base material
AA 6351
AISI steel 304

Tensile
strength(MPA)
150
515

Elongation (%)

Yield strength(MPa)

16
48

85
205

After the orthogonal array has been selected, the second step in Taguchi parameter design
is running the experiment. The aluminum alloy and steel was used in this investigation
for being one of the most popular materials in aeronautic applications. All the welds were
aluminum bar 16 mm and steel 304 also 16 mm.
For experimental set-up and design, continuous friction welding method was used. This
method required a machine resembling to a lathe equipped with a means of applying and
25

CHAPTER 3

DESIGN OF EXPERIMENT

controlling axial pressure. This all gear Lathe of having power 3Hp is made to function as
a friction welding machine by fitting the following additional components.
Hydraulic system equipped with manual pressure indicator used to measure forge load
and forging pressure.
One part hold in lathe chuck and other part to hold in grill chuck the given work piece
In experiment run on all gear lathe machine with different rotation speed, different
forging pressure with time variation.

3.5 Hydraulic equipments

3.5.1 Hydraulic device
The axial force needed to deliver the friction and forging pressures is produced by a
hydraulic cylinder which is located at the right side of the machine.

1. Tube 63 x 10 mm

Figure: 3.1 Hydraulic devices

5. Bush

2. Rod 25 x 290 mm

6. Plate 120 x 120 x 22

3. Piston 63 x 50

7. supporting jaw

4. Seal 63 x 63

8. 4 Nos. Stud

3.5.2 Hydraulic power pack

26

CHAPTER 3

DESIGN OF EXPERIMENT

The function of the hydraulic power pack is to collect all the important hydraulic
components into one freestanding module. The unit consists of a tank which acts as a
storage space for the hydraulic system fluid and electric motor driven hydraulic pumps
which pressurize the fluid and transmit power via the reducing and directional valves. A
vane type pump supplies pressures at 4000kg/cm2 for all machine operations, except the
forge pressure which is supplied by a mechanical or manual valve.
When changing oil, the tank is drained and the interior should be examined
through the inspection panel and all residue and sediment removed. The tank is filled
with oil to a level indicated by the oil level and it is important that the level is maintained.
Under normal conditions for continuous operation the fluid temperature should not
exceed 65C.

Figure: 3.2 Hydraulic Power Pack

3.6 Experiment set up :

The setup used for the present work was designed and constructed according to the
principals of continuous-drive welding machine. The spindle is driven by electric motor.
Axial forces are controlled by a hydraulic mechanical valve. In this machine up to 20 Ton
capacity a load cell is used to measure the axial force and controlled on a closed loop. An
industrial PC stores and displays all important parameters Axial Force, Spindle speed,
Displacement and Spindle torque.

27

CHAPTER 3

DESIGN OF EXPERIMENT

A drive motor capacity with 3hp and to the 1400 rpm speed with adequate torque
capacity was used for the friction welding of steel and aluminum bars of 16mm diameters
taking into account the friction and the upset pressures. Usually the structure is fairly
rigid to provide stability to the equipment working at high speeds and is driven by high
pressure forging. Modern equipment is automatic and allows all the parameters be
adjusted, controlled and monitored directly on the control panel. Figure 5 shows the
continuous drive friction welding setup.

Figure 3.3 Schematic Diagram Experiment Set Up

Figure 3.4(a)

28

CHAPTER 3

DESIGN OF EXPERIMENT

Figure 3.4(b)

Figure 3.4(c)
Figure 3.4 Experiment set up

3.7 Selection of Orthogonal Array

To select an appropriate orthogonal array for experiments, the total degrees of
freedom need to be computed. The degrees of freedom are defined as the number of
comparisons between process parameters that need to be made to determine which level
is better and specifically how much better it is. For example, a three-level process
parameter counts for two degrees of freedom. The degrees of freedom associated with
interaction between three process parameters are given by the product of the degrees of
freedom for the three process parameters. Basically, the degrees of freedom for the
orthogonal array should be greater than or at least equal to those for the process
parameters. In this study, an L9 orthogonal array was used. A total of nine experimental
runs must be conducted, using the combination of levels for each control factor as
indicated in Table 2. Therefore, there are six degrees of freedom owing to the three
welding parameters.
Once the degrees of freedom required are known, the next step is to select an
appropriate orthogonal array to fit the specific task. Basically, the degrees of freedom for
the orthogonal array should be greater than or at least equal to those for the process
parameters. In this study, an L9 orthogonal array was used. This array has twenty six
degrees of freedom and it can handle three-level process parameters. Each Friction
welding parameter is assigned to a column and twenty seven welding parameter

29

CHAPTER 3

DESIGN OF EXPERIMENT

combinations are available. A total of nine experimental runs must be conducted, using
the combination of levels for each control factor (AC) as indicated in Table 2.
Table 3.4 Orthogonal Array [L9]
Run
01
02
03
04
05
06
07
08
09

Level
B
1
2
3
1
2
3
1
2
3

A
1
1
1
2
2
2
3
3
3

C
1
2
3
2
3
1
3
1
2

The selected parameters are listed in Table 4 along with their applicable codes
and values for use in the Taguchi parameter design study.

3.8 TESTED WORK PIECE

Figure shows the specimens number 9A, 9B, 9C after they were tested and
removed from the tensile test machine. Effects of upset time and upset pressure on the
strength of joints were examined in welding of equal diameter parts. Friction time was
kept constant. The strength of joints was determined by tensile tests, and the results were
compared to those of fully machined specimens. The fracture occurred at the interface of
the dissimilar metal weld joint, strength of the weld joint was lesser than tensile strength
of AL6351 aluminum alloy and steel 304 at 230 MPa there was an unbounded region
around the centre of the fracture surface, although the aluminum alloy was partially
bonded to the stainless steel.
The welded specimens were machined according to ASTM section IX (200), and
subjected to tensile tests on a machine Fie Make universal testing machine ,UTS-40,at
DIVINE METALLURGICAL SERVICES PVT.LTD.

30

CHAPTER 3

DESIGN OF EXPERIMENT

Figure: 3.5 Before tested part after tested part

3.9 Experimental result tables:

The experiment that was performed is meant to investigate the feasibility of welding
between Stainless Steel and Aluminum. With taguchi optimizing methodology, enough
frictional heat is generated to create the weld joints. Inappropriate RPM, improper feed
(axial force to create proper friction) and inapt welding time may be the other drawbacks.
With the facility that I had for performing the experiment the only parameters that was at
my disposal to alter is the Rotational speed. Axial pressure and time variable depend on
process parameter level.
Table 3.5 Experiment result table with different parameter
Run

Level

Tensile strength (MPa)

Trial 1

Trial 2

Trial 3

Mean

01
02
03
04
05

950
950
950
1200
1200

200
210
230
200
210

8
9
10
9
10

65
84
86
59
85

91
91
93
50
59

52
96
63
123
109

69.33
90.33
80.66
77.33
84.33

06
07
08
09

1200
1500
1500
1500

230
200
210
230

8
10
8
9

85
64
111
137

87
96
122
124

107
107
108
99

93
89
117.33
120

31

CHAPTER 4

RESULTS AND VALIDATION

4
RESULT AND VALIDATION
4.1 RESULT AND DICUSSIONS
After conducting all the twenty seven experiments it is found that the welded
joints in different cases have different strength. In case of Aluminum bar 6351 and steel
304 diameter 16mm, there is no formation of any joint as the material got deformed even
before any joint get formed. This may be due to the fact that the surface velocity at the
interface of each work pieces may be too high which results in high deformation and due
the deformation, enough frictional heat cannot be generated and thus there is no welded
joint formation. The drill chuck has no role in friction welding. Its sole role is to give
mechanical support to the stainless bar and to protect it from any deformation.
This experiment shows some promise as there is formation of welded joint. But
the strength of the joint is not sufficient which is eminent from the fact that with a slight
pressure it gets broken. The poor strength of the joint may be a result of the high strain on
the work pieces during the experiment. The only reassuring fact in this case is that the
set-up is able to generate enough surface velocity, hence enough frictional heat to create a
joint between the two dissimilar materials Aluminum and stainless steel. In the case of
aluminum bar rotational speed should be high than experiment demonstrated that
deformation is very high. This may be happened due to the high stress generated at the
tool-work piece interface because same cross section area.
In the Taguchi method the results of the experiments are analyzed to achieve the
following objectives: (1) to establish the best or optimal condition for the product or
process, (2) to establish the contribution of individual factors, and (3) to estimate the
response under optimal conditions.

32

CHAPTER 4

RESULTS AND VALIDATION

4.2 TENSILE TESTS

After welding was performed, tensile tests were carried out to evaluate the tensile
strength of joints, besides parameter settings, optimization and qualification of welding
procedures and processes. The welded specimens were machined according to ASTM
A370, and subjected to tensile tests on a machine with a load cell capacity of 100 KN at
room temperature of 25C, and a test speed of 1 mm/minute.
The effect of friction time and friction pressure on the strength of joints was
examined in welding of equal diameter parts. Upset time was kept constant. The strength
of joints was determined by tensile tests, and the results were compared to those of fully
machined specimens. Obtained tensile strength for all the three corresponding trials is
given in the table 4.Tensile strength of the joints was estimated dividing the ultimate load
by area of the specimen. The fracture occurred at the interface of the dissimilar metal
weld joint, strength of the weld joint was lesser than tensile strength of AA6351
aluminum alloy 230Mpa, there was an unbounded region around the centre of the fracture
surface, although the aluminum alloy was partially bonded to the stainless steel.
As friction time and friction pressure for the joints are increased, tensile strength
of the joints also increases Table 6, but, strength of the joints passes through a maximum,
then, when friction time and friction pressure for the joints are further increased, tensile
strength of the joints decreases. Thus, it is shown that friction time and friction pressure
have a direct effect on joint y time and friction pressure affect cue of the metals the weld
reduces the joint quality, but it was slightly softened. The fracture mechanism of joints
with a shorter time may be different from that of joints with a longer friction time.
After welding was performed, tensile tests were carried out to evaluate the
mechanical properties of joints, besides parameter settings, optimization and qualification
of welding procedures and processes.

33

CHAPTER 4

RESULTS AND VALIDATION

Figure: 4.1 Universal Testing machine

The welded specimens were machined according to ASTM section IX (200), and
subjected to tensile tests on a machine Fie Make universal testing machine ,UTS-40, at
DIVINE METALLURGICAL SERVICES PVT.LTD.

4.3

Analysis experimental data:

This array is designated by the symbol L9, and is used to design experiments with up to
twenty two Level factors. The array has 9 rows and 4 columns; each row represents a trial
condition with factor levels indicated by the numbers in the row.
Standard deviation:

1
4

=1 (

The signal to noise ratio (S/N ratio) was used to measure the sensitivity of the quality
characteristic being investigated in a controlled manner. In Taguchi method, the term
signal' represents the desirable effect (mean) for the output characteristic and the term
34

CHAPTER 4

RESULTS AND VALIDATION

noise' represents the undesirable effect (signal disturbance, S.D) for the output
characteristic which influence the outcome due to external factors namely noise factors.
The preferred parameter settings are then determined through analysis of the signal-tonoise (SN) ratio where factor levels that maximize the appropriate SN ratio are optimal.
There are three standard types of SN ratios depending on the desired performance
response.
In this array, it can be seen that any number of repeated observations (trials) may be used.
Ti, j represents the different trials with i = experiment number and j = trial number. It
should be noted that the Taguchi method allows for the use of a noise matrix including
external factors affecting the process outcome rather than repeated trials, but this is
outside of the scope of this article.
To determine the effect each variable has on the output, the signal-to-noise ratio, or the
SN number, needs to be calculated for each experiment conducted. The calculation of the
SN for the first experiment in the array above is shown below for the case of a specific
target value of the performance characteristic. In the equations below, yi is the mean
value and si is the variance. yi is the value of the performance characteristic for a given
experiment.

For the case of minimizing the performance characteristic, the following definition of the
SN ratio should be calculated:

For the case of maximizing the performance characteristic, the following definition of the
SN ratio should be calculated:

35

CHAPTER 4

RESULTS AND VALIDATION

Table 4.1 S/N Ratio of experiment Reading

Level

Tensile strength
(MPa)
Trial Trial Trial
1
2
3
65
91
52

Mean

Standard
deviation

S/N
Ratio

69.33

10.65

17.36

96

90.33

4.92

25.27

93

63

80.66

12.81

15.92

59

50

123

77.33

8.44

18.37

10

85

59

109

84.33

20.41

12.32

230

85

87

107

93

9084

19.45

1500

200

10

64

96

107

89

18.23

13.37

08

1500

210

111

122

108

117.33

12.20

19.66

09

1500

230

137

124

99

120

15.74

17.69

Run
A

01

950

200

02

950

210

84

91

03

950

230

10

86

04

1200

200

05

1200

210

06

1200

07

After calculating the SN ratio for each experiment, the average SN value is
calculated for each factor and level. This is done as shown below for Parameter 1 (T1) in
the array:

SN1 =

SN2 =

SN3 =

17.36+25.27+15.92
3
18.37+23.32+19.45
3
13.77+19.66+17.64
3

= 19.51
= 16.71
= 16.89

Once these SN ratio values are calculated for each factor and level, they are
tabulated as shown below and the range R (R = high SN - low SN) of the SN for each
parameter is calculated and entered into the table. The larger the R value for a parameter,
the larger the effect the variable has on the process. This is because the same change in
signal causes a larger effect on the output variable being measured.

36

CHAPTER 4

RESULTS AND VALIDATION

Once these SN ratio values are calculated for each factor and level, they are tabulated as
shown below and the range R (R = high SN - low SN) of the SN for each parameter is
calculated and entered into the table. The larger the R value for a parameter, the larger the
effect the variable has on the process. This is because the same change in signal causes a
larger effect on the output variable being measured.
Table 4.2 Optimum Parameter
Sr. no
01
02
03
(Range)
RANK

RPM
19.51
16.75
16.89
2.8
2

PRESSURE
16.5
19.08
17.67
2.58
3

TIME
18.82
20.42
14.00
6.42
1

Please refer to the Worked out Example for a numeric example of how the data
analysis procedure described here is applied. It can be seen that deposition rate has the
largest effect on the friction time and that forging pressure has the smallest effect on the
processor yield.
It is noticed that optimum parameters with sufficient friction pressure and friction
time results in a strong bonding at the interface of the dissimilar metal joints which
provides greater weld strength.

4.4

Analysis of variance:

In design of experiment the results are analyzed due to one or more of the following three
objectives.
1. To establish the best or the optimum condition for a product or a process.
2. To estimate the contribution of individual factors.
3. To estimate the response under the optimum condition.
The optimum condition is identified by studying the main effects of each of the factors.
The main effects indicate the general trends of the influence of the factors. Knowing the
characteristics, i.e. whether a higher or lower value produces the preferred results, the
level of the factors which are expected to produce the best results can be predicted.
37

CHAPTER 4

RESULTS AND VALIDATION

The analysis of variance (ANOVA) is the statistical treatment most commonly applied to
the results of the experiments to determine the percentage contribution of each factors.
Study of ANOVA table for a given analysis helps to determine which of the factors need
control and which do not. Once the optimum condition is determined, it is usually good
practice to run a confirmation experiments. In case of fractional factorial some of the
tests of full factorial are conducted. The analysis of the partial experiment must include
an analysis of confidence that can be placed in the results. So analysis of variance is used
to provide a measure of confidence. Analysis provides the variance of controllable and
noise factors. By understanding the source and magnitude of variance, robust operating
condition can be predicted.

MINITAB SOFTWARE:
Minitab is a statistics package. It was developed at the Pennsylvania State University by
researchers Barbara F. Ryan, Thomas A. Ryan, Jr., and Brian L. Joiner in 1972. Minitab
began as a light version of OMNITAB, a statistical analysis program by IITE. Minitab is
distributed by Minitab Inc, a privately owned company headquartered in State College,
Pennsylvania, with subsidiaries in Coventry, England (Minitab Ltd.) France. Today,
Minitab is often used in conjunction with the implementation of Six Sigma, CMMI and
other statistics-based process improvement methods. Minitab 16 is the latest version of
the software.

Uses of Minitab:
Data and File Management- spreadsheet for better data analysis.
Regression Analysis
Power and Sample Size
Tables and Graphs
Multivariate Analysis- includes factor analysis, cluster analysis, correspondence

analysis
Nonparametric- various tests including sing test, runs test, Friedman test, etc.
Statistical Process Control
Measurement System Analysis

Analysis of Variance- to determine the difference between data points.[29]

38

CHAPTER 4

RESULTS AND VALIDATION

Figure 4.2 Graphical analysis tensile strength with different parameter

From the above experimental works results and study revealed that Rotational speed,
forging pressure, friction time how much affected tensile strength.
1. With the increase of Rotation speed than increases tensile strength of joint.
2. With the increase forging pressure after some limit tensile strength remain
constant.

4.5 Radiography test results:

After welding was performed, non distractive tests were carried out to evaluate
the discontinuity of joints and density of the film measured and confirmed to be between
1.5 to 4.0. Besides parameter settings, optimization and qualification of welding
procedures and processes. The welded specimens were machined according to ASME
SEC-V, ARTICLE 2 & 22, and subjected to radiography tests of SWSI technique, at
Sigma Inspection & Testing Pvt. Ltd. (An ISO 9001- 2008 certified company).

39

CHAPTER 4

RESULTS AND VALIDATION

Industrial radiography involves exposing a test object to penetrating radiation so

that the radiation passes through the object being inspected and a recording medium
placed against the opposite side of that object. For thinner or less dense materials such as
aluminum, electrically generated x-radiation (X-rays) is commonly used, and for thicker
or denser materials, gamma radiation is generally used.
The results of radiography test which were observed during the experiment were
tabulated which are shown in below:
Table 4.3 NDT TEST REPORT
Sr. No

Test parameter

Result

01

Radiography test

No significant defect
Indications are noticed.
Hence acceptable.

4.6 Validation
Validation of friction welding to aluminum 6351 and steel 304 to compare with friction
welding 6082 and steel 304.
Table 4.4 chemical properties of AA 6082 and AA 6351 with steel 304 [13]
Zn

Element
AA
6082
Element
AA 6351

AISI 304
STAINLESS
STEEL

Si

Zn

Mg

Mn

Fe

Cu

Cr

Al

0.75

0.080

0.718

0.536

<0.100

0.052

<0.001

0.080

Balance

Si

Zn

Mg

Mn

Fe

Cu

Ti

Sn

Ni

Pb

0.9
07

0.89

0.586

0.65

0.65

0.086

0.015

0.003

0.002

0.001

Si

Mn

Cr

Ni

0.38

0.024

0.036

1.67

0.054

18.2

8.0

To investigated friction wielding on dissimilar material 6351 and stainless steel 304 by
taguchi methodology. For this purpose to validated other material 6058 and steel 304.
40

CHAPTER 4

RESULTS AND VALIDATION

Majorly different both material AA 6351 and 6058 chemical composition and mechanical
properties. We are investigates and validated to tensile strength of dissimilar material
AA 6351 and steel 304 to AA6082 and steel 304.
We are validated value of tensile strength of dissimilar friction welding 6351 to 6082.
SHUBHAVARDHAN R.N & SURENDRAN S are study about friction welding to join
stainless steel and aluminum materials with The welded specimens were machined
according to ASTM E 8M (2004), and subjected to tensile tests on a machine with a load
cell capacity of 100 KN at room temperature of 25C, and a test speed of 1 mm/minute.
The initial step was to examine fracture surfaces for any noticeable difference in fracture
mechanism between unsound joints with shorter and longer friction times. Obtained
tensile strength results were given in Table.
Table 4.5 Obtained tensile strength results AA 6082 and steel 304

Trials

Rotating
speed

Friction time (s)

Upset pressure
MPa

Tensile
Strength

1
2
3

1400
1400
1400

3
5
7

210
210
210

136.43
188.40
149.6

Table 4.6 Obtained tensile strength results AA 6351 and steel 304
Trials

Rotating
speed

Friction time (s)

Upset pressure
MPa

Tensile
Strength

1
2
3

1400
1400
1400

8
9
10

210
230
200

107
108
99

REMARK
Finally we validated of friction welding strength of dissimilar material AA 6082 and
AA6351 with steel 304. We compare friction welding parameter like rotation speed,
friction time, forging pressure and tensile strength of material show table 1 and table 2.
We are conclude that some variation of strength of joining material in this some reason
direct effect to strength of joining.
41

CHAPTER 4

RESULTS AND VALIDATION

1. Different Chemical composition and mechanical properties of AA6082 aluminum

alloy and AA 6351.
2. The results of this study have fundamental importance for the understanding and
comprehension of the main characteristics of friction welding process, in this
some error in experiment set up.
3. Error between experimental readings.

42

CHAPTER 5

CONCLUSION

5
CONCLUSION
5.1 Conclusion
In the present study, stainless steel (AISI 304) and aluminum 6351 materials were welded
successfully. The welding process was investigated by tensile testing and Non distractive
test (radiography) measurements with the following results:
1. Optimum welding parameters should be properly selected in the friction welding
of dissimilar material parts.
2. Tensile strengths for stainless steel 304 and aluminum 6351 parts yielded a
positive result when compared to those of base metals. The joint strength
increased and then decreased after reaching a maximum value, with increasing
friction time. Sufficient heat to obtain a strong joint could not be generated with a
shorter friction time. A longer friction time caused the excess formation of an
intermetallic layer. However, some of the welds showed poor strength depending
on some accumulation of alloying elements at the interface, which are the result
of a temperature rise and the existence of intermetallic layers such as FeAl.
3. It is showed by the results of tension mechanical tests that presented mechanical
properties which are not possible to achieve by means of fusion welding
processes.
4. This presented an application of the parameter design of the Taguchi method in
the optimization of Friction welding parameters. The following conclusions can
be drawn based on the experimental results of this study:

Taguchis robust

orthogonal array design method is suitable to analyze this problem.

43

CHAPTER 5

CONCLUSION

5. It is found that the parameter design of Taguchi method provides a simple,

systematic, and efficient methodology for the optimization of the Friction welding
parameters.

6. Finally I have also performed NDT test in radiography and measure no

signification discontinuity of friction welding with dissimilar material.

44

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