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Mechanical properties of friction welded 6063 aluminum alloy and austenitic stainless steel

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Abstract

Friction welding of dissimilar metal combination of aluminum alloy and austenitic stainless steel was examined to investigate the effect of welding conditions on mechanical properties of the dissimilar metal combination. The welded joints were produced by varying forge pressure (F g), friction pressure (F r), and burn-off length (B). The joints were subjected to mechanical testing methods such as the tension, notch Charpy impact tests. The tensile strength and toughness decrease with an increase in friction pressure. The tensile strength decreases with an increase in burn-off length at a low forge pressure while tensile strength increases with an increase in burn-off length at a high forge pressure. The tensile failure of the welded joint occurred in aluminum alloy just away from interface in the thermo-mechanically affected zone indicates good joint strength at the condition of low friction pressure, high forge pressure, and high burn-off length. The maximum tensile strength was observed with low friction pressure and high forge pressure. The tensile strength of dissimilar joint is approximately equal to tensile strength of 6063 aluminum alloys at the condition of low friction pressure, high forge pressure, and high burn-off length. The tensile and impact failure of joints was examined under scanning electron microscope and failure modes were discussed.

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Acknowledgments

The authors express their gratitude to Defence Research and Development Organization for the microstructure analysis to carry out this programme. The authors are thankful to Dr. G. Madhusudhan Reddy, DMRL for his continued encouragement. The author also thanks to Prof. K. Prasada Rao (IIT M) for the support to conduct the experimental work. One of the authors (P. Sammaiah) is thankful to the Principal and the management of S.R. Engineering College, Warangal for their continued support during this work.

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Authors and Affiliations

  1. Department of Mechanical Engineering, S R Engineering College, Warangal, 506371, Andhra Pradesh, India

    P. Sammaiah & Arjula Suresh

  2. Department of Mechanical Engineering, National Institute of Technology, Warangal, 506004, Andhra Pradesh, India

    G. R. N. Tagore

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  1. P. Sammaiah
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  2. Arjula Suresh
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  3. G. R. N. Tagore
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Correspondence to P. Sammaiah.

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Sammaiah, P., Suresh, A. & Tagore, G.R.N. Mechanical properties of friction welded 6063 aluminum alloy and austenitic stainless steel. J Mater Sci 45, 5512–5521 (2010). https://doi.org/10.1007/s10853-010-4609-y

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  • DOI: https://doi.org/10.1007/s10853-010-4609-y

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