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ABSTRACT
WELDING RESEARCH
Introduction
Recent technological advances have
necessitated the development of new materials as well as new methods for joining
them. An example of such a material is the
metal matrix composite (MMC), which is
essentially a structure consisting of a combination of two or more macro components that dissolve within one another.
Metal matrix composites, which both have
a high elastic modulus of ceramic and high
metal ductility, are used with conventional
metallic materials in fields such as aircraft
and aerospace engineering, as well as defense and automotive industries. Ratios
such as strength/weight and strength/density play an important role in metal matrix
composites, and in so doing, they add
something novel and innovative to the
scope of structural materials (Refs. 1, 2).
As the demand for these new materials
grows, studies related to the production
and mechanical properties of composite
materials have become a focus of re-
KEYWORDS
Friction Welding
Weldability Testing
Metal Matrix Composite
Carbon Steel
WELDING RESEARCH
Fig. 5 Optical microstructures of the weld zone and HAZ of the experiment 3 (200). A HAZ (side
of MMC); B weld zone; C HAZ (side of AISI 1030).
WELDING RESEARCH
particles transfer to and are trapped in spiral arm regions located near the stationary
boundary of friction welded joints. The
tensile strengths of postweld heat treated
MMC/MMC joints produced using a friction pressure of 280 MPa were significantly stronger than as-received MMC
base material (Ref. 14).
In their study, Lin et al. (2002) were able
to successfully conduct friction welding between two composite materials with the
same matrix but a different reinforced material. Composite materials are SiC and
Al2O3 reinforced A7005 aluminum alloy.
For composite materials, the following were
used: size 6 and 15 m, SiC particulate volume percentage of 10%, and 15 m Al2O3
ceramic particulate of the same volume percentage. Consequently, the use of a SiC particulate led to a concentration of reinforcement particulate in the HAZ. This results in
an increase in hardening values in the plastic region, weakening welding strength, and
narrowing HAZ (Ref. 15).
Lee et al. (2004) were able to achieve
friction welding between a TiA1 alloy and
AISI 4140 for a friction time of 3050 s,
Fe
0.12
Si
7
Ti
0.2
Mn
0.03
Zn
0.02
Cu
0.02
Mg
0.28
Ni
0
Cr
0
Ni
0.100
Cr
0.082
Si
0.143
Mn
0.636
P
0.011
Cu
0.167
Mo
0.011
Nb
<0.002
Fe
98.511
Yield Strength
(MPa)
Tensile Strength
(MPa)
AISI 1030
6% Al/SiCp
477.68
103.76
725.46
149.57
Elongation
(%)
5.20
0.025
Hardness
(HV50)
232.3
64.5
Experimental Procedure
In this study, SiCp-reinforced A356
aluminum matrix composite and AISI
1030 steel were used. A SiC particulate-reinforced A316 aluminum matrix composite was prepared using the vortex method.
In the Al/SiC composite material, some
reactions take place between the matrix
and reinforcement material during casting. The Al4C3, which formed as a result
of these reactions, renders the welding
very brittle. Very high heat input makes
Al4C3 even more pronounced. The compound takes form at a temperature between 700 and 1400C (Refs. 1, 19). To
prevent brittleness of the composite material caused by the Al4C3 compound, the
vortex method that does not require very
high heat input is used. The casting was
carried out using the stir casting method at
700C.
The chemical composition of the A356
aluminum alloy is presented in Table 1. It
should be noted that the SiC particulate
Friction Pressure
(Pf) (MPa)
Friction Time
(tf) (s)
Upset Pressure
(Pu) (MPa)
Upset Time
(tu) (s)
Experiment 1
Experiment 2
Experiment 3
Experiment 4
Experiment 5
Experiment 6
Experiment 7
Experiment 8
40
40
40
20
20
20
20
20
4
6
10
6
12
4
6
8
40
40
40
40
40
60
60
60
4
4
4
4
4
4
4
4
WELDING RESEARCH
WELDING RESEARCH
4.763
points taken from the welded joint zone
O
K
8.770
0.193
zone C was carried out. In Fig. 10, the lines
Fe K
15.747
100.000
94.326
and points used in the EDS analysis are revealed, and Fig. 11 depicts the results. In
WELDING JOURNAL 227-s
WELDING RESEARCH
Fig. 13 Linear EDS analysis results of fracture surface on the side of AISI
1030 material.
WELDING RESEARCH
1. Zhu, Z. A. 1988. Literature survey on fabrication methods of cast reinforced metal composites. Edited by S. G. Fishman and A. K.
Dhingra. ASM/TMS Committee, World Materials Congress, Sept. 2430, Chicago, Ill.
2. Han, N. L., Yang, J. M., and Wang, Z. G.
2000. Role of real matrix strain low cycle fatigue
life of a SiC particulate reinforced aluminum
composite. Scripta Mater. 43: 8015.
3. Zhang, X. P., Quan, G. F., and Wei, W.
1999. Preliminary investigation on joining performance of SiC-reinforced aluminum metal
matrix composite by vacuum brazing. Composites Part A 30: 8237.
4. Zhang, X. P., Ye, L., Mai, Y. W., Quan, G.
F., and Wei, W. 1999. Investigation on diffusion
bonding characteristics of SiC particulate reinforced aluminum MMC. Composites Part A 30:
141521.
5. Meshram, S. D., Mohandas, T., Madhusudhan, and Reddy, G. 2008. Friction welding of dissimilar pure metals. J. Mater. Process
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