Rotary Friction Welding of Aluminum Alloy Tube to Tube with Edge Using External Tool

Abstract

This friction welding process is characterized by the fact that there are no springs or deformations at the welding point, neither from the outside nor from the inside, and an unmistakable and ideal welding shape is obtained. The experiment was conducted on a flat sample without grooves, and it was welded, but it was very weak. Then grooves were made on the outer edge, and the welding took place, and it was a stronger weld. The idea was to increase the grooves to the end of the entire thickness of the sample, not just on the edge, and it was the strongest weld and optimal in shape. Several experiments were also performed. Experiments were conducted at different speeds until the four speeds (630, 800, 1000, 1250 rpm) used in this thesis were reached, the best of which was 1000 rpm. Experiments were conducted at different forces, and the four forces (20, 25, 30, 35 kgF ) used became the best among those used in many experiments. The best of them was the force of 30 kgF (300 Newton), at a fixed time of 4 minutes, while the temperature was 200oC on surface welding at 4 minutes the welding process. For every speed and force, this appeared in the tensile test conducted on the samples after welding and was demonstrated that tensile dismantled force was 6160 N at 30 kgF of welding pressure. The study proved the success of this method.

Keywords

• aluminum alloy
• external tool
• rotary friction welding
• tube to tube