Experimental and Finite Element Analysis of Rotary Friction Welded Aluminum Rods

Abstract

Welding can be defined as the principal joining method for metals. Welding can be broadly classified  into Fusion welding and Solid-State welding. Material like brass, copper and especially aluminum cannot be joined using conventional welding techniques. Conventional welding techniques generates additional scrap, poor weld strength, cracks, porosity, dangerous to environment, slag insertion, and unable to weld materials of different mechanical properties that is why rotary friction welding technique which is a type of Solid-State Welding used extensively in joining metallic and non- metallic specimen with effectiveness. The objective of this work is to give a better-quality Weld solution using rotary friction welding technique and its comparison with the unwelded specimen. In this work Vertical milling machine powered by motor, a continuous drive method was utilized for Welding of Aluminum alloy rods of varying diameter from 10mm to 12mm respectively. In this work three step methodology is followed. Firstly, dimensions, geometry and rotary friction welded specimen of Aluminum were prepared on vertical milling machine. Secondly destructive testing is performed for the tensile, compression, fatigue, hardness, and impact strength of the welded and unwelded specimen. Finally finite element analysis is carried out using experimental data resulted that the ultimate Tensile Strength of rotary friction welded specimen is 68% as that of unwelded specimen. As for Compression testing a significant decrease in    length of 1.33% and increase in area of 8.88% is observed While in case of unwelded specimen compression is small i.e. Decrease in length is 0.61%, increase in area is 1.29%.
Keywords: Rotary Friction Welding, Destructive Testing, Finite Element Analysis