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Thermal behavior analysis and mechanical characterization of friction stud welded AISI 304/AA6063 joints

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Abstract

This study investigates the joining efficiency by analyzing the thermal behavior of friction stud welding of AISI 304 stainless steel and AA6063 alloys. Effects of the three most influential process variables including rotational speed (RS), friction time (FT) and friction pressure (FP) have been investigated on the thermal profile of joint interface region of dissimilar metals using peak temperature during the friction welding process. Thermal analysis of the joint interface is performed using finite element analysis (FEA) and finite difference method (FDM). The influence of different process variables has also been analyzed on the heating and cooling curves of the interface region at different moments. Microstructural analysis reveals that variation in the peak temperature also varies the grain size in the intermetallic phases formed in the interface region. At higher peak temperatures, finer grains yield a stronger bond between dissimilar metals. Peak values of the impact strength have been obtained at higher levels of RS, FT and FP. Maximum Vickers hardness of 325 HV has been observed at the joint interface, which has more than both parent metals.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Mepco Schlenk Engineering College, Sivakasi, 626005, India

    N. Rajesh Jesudoss Hynes, D. Jones Joseph Jebaraj & N. J. Vignesh

  2. Department of Mechanical Engineering, AAA College of Engineering and Technology, Sivakasi, 626005, India

    Meby Selvaraj

  3. Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890, Pakistan

    Muhammad Asad Ali

  4. Department of Industrial and Manufacturing Systems Engineering, The University of Hong Kong, Hong Kong, China

    Muhammad Huzaifa Raza

  5. Design, Manufacturing & Engineering Management, University of Strathclyde, Glasgow, G1 1XJ, Scotland, UK

    Catalin I. Pruncu

  6. Department of Mechanical Engineering, P.S.R Engineering College, Sivakasi, 626140, India

    P. Shenbaga Velu

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  1. N. Rajesh Jesudoss Hynes
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Correspondence to N. Rajesh Jesudoss Hynes.

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Rajesh Jesudoss Hynes, N., Jones Joseph Jebaraj, D., Selvaraj, M. et al. Thermal behavior analysis and mechanical characterization of friction stud welded AISI 304/AA6063 joints. J Braz. Soc. Mech. Sci. Eng. 44, 114 (2022). https://doi.org/10.1007/s40430-022-03412-2

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