FRICTION WELDING

Presented by: Kapil Mahajan Ankit Dua Sandeep

Work taken over by group

1. Convert a simple lathe machine to use of friction welding. 2. To study the effect of various parameters on Friction welding.

3. Study the change In microstructure of materials due to heat generation

Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the work pieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. Many different energy sources can be used for welding, including a gas flame, an electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding may be performed in many different environments, including open air, under water and in outer space.

Electrical

Solid State Welding

Chemical
Friction
Mechanical

Pressure & Deformation

Friction Weld

A simple explanation defines the friction welding process as rotating one component against a fixed component under pressure. This action efficiently prepares and cleans the weld interface, and generates sufficient low temperature, frictional heat, for at least one of the materials to become plastic at the joint interface. This "Solid State" (nonmelting), joining process produces a merging between the materials via the heat developed by the induced rubbing motion, and the applied load between the two surfaces. At this point, rotation stops rapidly and the components are forged together.

DEFINITION OF FRICTION WELDING

Friction welding is a solid state joining process that produces coalescence by the heat developed between two surfaces by mechanically induced surface motion.

CATEGORIES OF FRICTION WELDING

Continuous Inertia

drive

Continuous Drive

CONTINUOUS DRIVE FRICTION WELDING

One of the workpieces is attached to a rotating motor drive, the other is fixed in an axial motion system. One work piece is rotated at constant speed by the motor. An axial or radial force is applied.

Workpieces Motor Non-rotating vise

Spindle Chuck Brake

Hydraulic cylinder

Continuous Drive

CONTINUOUS DRIVE FRICTION WELDING

The work pieces are brought together under pressure for a predeter-mined time, or until a preset upset is reached. Then the drive is disengaged and a break is applied to the rotating work piece.

Workpieces Motor Non-rotating vise

Spindle Chuck

Hydraulic cylinder

Brake

INERTIA WELDING PROCESS DESCRIPTION

1.

One of the work pieces is connected to a flywheel; the other is clamped in a non-rotating axial drive The flywheel is accelerated to the welding angular velocity. The drive is disengaged and the work pieces are brought together Frictional heat is produced at the interface. An axial force is applied to complete welding.

2.

Motor Flywheel

Non-rotating chuck Workpieces

3.

1.

Spindle

Chuck Hydraulic cylinder

1. 2. 3. 4. 5. 6. 7. 8.

Original diameter of pulley available at shaft end: 5 inches Original diameter of pulley available at lathe end: 8 inches Diameter of pulley used at motor end: 8 inches Diameter of pulley used at lathe end : 5 inches No change was made to the gear ratio Motor with .5 horse power was tried but was unsuccessful Finally motor with 1 horse power was used RPM achived at chuck :1950

1. The properties of the steel depends upon the microstructure. decreasing the size of the grains and decreasing the amount of pearlite improves the strength, ductility and the toughness of the steel. 2. The dark regions are the cementite. It is made up from a fine mixture of ferrite and iron carbide, which can be seen as a "wormy" texture. 3. The light colored region of the microstructure is the ferrite. The grain boundaries between the ferrite grains can be seen quite clearly. 4. The group agrees to the fact that strength increases with decrease in pearlite structure because in our project we see after the welding pearlite structure reduces and torsional strength increases

1. Length of specimen before welding: 166.0mm(MS), 170(AL) 2. Length of specimen before testing :160.8mm (MS), 160(AL) 3. Length of specimen after testing : 166.9 mm(MS) ,172(AL) 4. Diameter of specimen :16 mm(MS), 8mm (AL)

s t r e s s

strain

During tensile testing of a material sample, the stressstrain curve is a graphical representation of the relationship between stress, derived from measuring the load applied on the sample, and strain, derived from measuring the deformation of the sample, i.e. elongation, compression, or distortion. The slope of stress-strain curve at any point is called the tangent modulus; the slope of the elastic (linear) portion of the curve is a property used to characterize materials and is known as the Young's modulus. The area under the elastic portion of the curve is known as the modulus of resilience. The nature of the curve varies from material to material. The following diagrams illustrate the stressstrain behaviour of typical materials in terms of the engineering stress and engineering strain where the stress and strain are calculated based on the original dimensions of the sample and not the instantaneous values.

Mild steel generally exhibits a very linear stressstrain relationship up to a well defined yield point. The linear portion of the curve is the elastic region and the slope is the modulus of elasticity or Young's Modulus. After the yield point, the curve typically decreases slightly .As deformation continues, the stress increases on account of strain hardening until it reaches the ultimate strength. Until this point, the cross-sectional area decreases uniformly because of Poisson contractions. The actual rupture point is in the same vertical line as the visual rupture point. However, beyond this point a neck forms where the local cross-sectional area decreases more quickly than the rest of the sample resulting in an increase in the true stress. ,curve is plotted in terms of true stress and true strain the stress will continue to rise until failure. Eventually the neck becomes unstable and the specimen ruptures (fractures).

l o a d

displacement

1. Max Tensile strength of mild steel: 45kn 2. Max Torsional strength of mild steel: 50kn 3. Tensile strength of our tested specimen: 30kn 4. Torsional strength of our tested specimen: 57.6kn 5. Max tensile strength of aluminum: 35 kn 6. Max torsional strength of aluminum: 29kn 7. Max torsional strength of our tested specimen: 37kn

MILD STEEL BEFOR WELDI NG

ALUMI NUM BEFOR E WELDI NG MILD STEEL AFTER WELDI NG

95

94

95

95

94

96

79

80

80

80

78

80

120

116

95

95

96

94

ALUMI NUM AFTER WELDI NG

94

90

80

79

79

80

AWS Welding Handbook

1. ENVIORMENT FRIENDLY 2. SAFE FOR USE 3. CAN BE USED FOR MASS PRODUCTION 4. MOST IMPORTANTLY IT CAN BE VIEWED BY NAKED EYE 5. SMALL HEAT AFFECTED ZONES 6. JOINT ENDS UP STRONGER THAN PARENT MATERIAL 7. LOW ENERGY CONSUMPTION 8. CHEAPER IN COST 9. SHORT TIME CYCLE 10. LESS PREPRATION OF SPECIMEN

1. Join highly dissimilar metal combination to optimize your products' quality and properties.

2. Little cost variation with weld size.

3. Save labor, material, and operations through near net size design. 4. No part length problems.

WIDE APPLICATIONS

Bimetallic Engine Valve Brake Calliper Steering Shaft Air Brake Push Pad Assembly Universal Joint Yoke Drive Axle Shaft Shift Lever Turbine Shaft Diesel Injector Helicopter Rotor Shaft Twist Drill ,Lathe Spindle Blank Drill Pipe Gear Hub Valve Body Eccentric Shaft

DISADVANTAGE OF FRICTION WELDING

Grain Growth A wide T will exist between base metal and HAZ. Preheating and cooling methods will affect the brittleness of the metal in this region Inclusions Impurities or foreign substances which are forced into the weld puddle during the welding process. Has the same effect as a crack. Segregation Condition where some regions of the metal are enriched with an alloy ingredient and others arent. Can be prevented by proper heat treatment and cooling. Porosity The formation of tiny pinholes generated by atmospheric contamination. Prevented by keeping a protective shield over the molten weld puddle. Residual Stresses Rapid heating and cooling results in thermal stresses detrimental to joint strength.

1. 2. 3. 4.

COST OF RAW MATERIAL PURCHASED: RS 350 MONEY SPENT ON SPECIMEN TESTING : RS 1200 MOTOR PURCHASED FOR: RS 800 MISCLENIOUS EXPENSES: RS 500

THANKS