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Characteristics of Friction Welding Between Solid Bar of 6061 Al Alloy and Pipe of Al-Si12CuNi Al Cast Alloy

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Abstract

This paper describes the characteristics of friction welding between a solid bar of 6061 Al alloy and a pipe of Al-Si12CuNi (AC8A) Al cast alloy. When the joint was made by a continuous drive friction welding machine (conventional method), the AC8A portion of the joint showed heavy deformation and the AA6061 showed minimal deformation. In particular, the joint could not be successfully made with following conditions, because AC8A pipe side crushed due to insufficient friction heat or high pressure: a short friction time such as 0.3 s, high friction pressure such as 100 MPa, or high forge pressure such as 150 MPa. The heavy deformation of AC8A side was caused by increasing friction torque during braking. To prevent braking deformation until rotation stops, a joint was made by a continuous drive friction welding machine that has an electromagnetic clutch. When the clutch was released, the relative speed between both specimens simultaneously decreased to zero. When the joint was made with friction pressure of 25 MPa, friction time of 0.3 s, and forge pressure of 125 MPa, the joining could be successfully achieved and that had approximately 16% efficiency. In addition, when the joint was made with friction pressure of 25 MPa, friction time of 0.7 s, and forge pressure of 125 MPa, it had approximately 54% efficiency. However, all joints showed the fracture between the traveled weld interface and the AC8A side, because the weld interface traveled in the longitudinal direction of AC8A side from the first contacted position of both weld faying surfaces. Hence, it was clarified that the friction welding between a solid bar of AA6061 and a cast pipe of AC8A was not desirable since the traveling phenomena of the weld interface were caused by the combination of the shapes of the friction welding specimens.

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Acknowledgments

This research was partially supported by the Ministry of Education, Culture Sports, Science and Technology, Japan, Grant-in-Aid for Scientific Research (C) (MEXT KAKENHI), Grant Number 22560093, 2010-2012. We wish to thank the staff members of the Machine and Workshop Engineering at the Graduate School of Engineering, University of Hyogo.

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  1. H. Sakaguchi

    Present address: TOWA Corporation, Kyoto, Japan

Authors and Affiliations

  1. Department of Mechanical and System Engineering, Graduate School of Engineering, University of Hyogo, 2167 Shosha, Himeji, Hyogo, 671-2280, Japan

    M. Kimura, M. Kusaka & K. Kaizu

  2. University of Hyogo, 2167 Shosha, Himeji, Hyogo, 671-2280, Japan

    H. Sakaguchi

  3. Department of Mechanical Engineering, Kushiro National College of Technology, 2-32-1 Otanoshike-Nishi, Kushiro, Hokkaido, 084-0916, Japan

    T. Takahashi

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Kimura, M., Sakaguchi, H., Kusaka, M. et al. Characteristics of Friction Welding Between Solid Bar of 6061 Al Alloy and Pipe of Al-Si12CuNi Al Cast Alloy. J. of Materi Eng and Perform 24, 4551–4560 (2015). https://doi.org/10.1007/s11665-015-1735-3

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