Experimental and analytical investigation on friction welding dissimilar joints for aerospace applications

R. Ramesh Kumar; J.M. Babu; Bahaa Saleh; H. Fayaz; A. Chandrashekar; Tanya Gera; Kottakkaran Sooppy Nisar; C Ahamed Saleel

Ain Shams Engineering Journal (Mar 2023)

Experimental and analytical investigation on friction welding dissimilar joints for aerospace applications

R. Ramesh Kumar,
J.M. Babu,
Bahaa Saleh,
H. Fayaz,
A. Chandrashekar,
Tanya Gera,
Kottakkaran Sooppy Nisar,
C Ahamed Saleel

Affiliations

R. Ramesh Kumar: Vel Tech Rangarajan Dr.Sagunthala R&D Institute of Science and Technology, Chennai, India; Corresponding authors.
J.M. Babu: Vel Tech Rangarajan Dr.Sagunthala R&D Institute of Science and Technology, Chennai, India
Bahaa Saleh: Department of Mechanical Engineering, College of Engineering, Taif University, P.O. Box 11099, Taif 21944, Saudi Arabia
H. Fayaz: Modeling Evolutionary Algorithms Simulation and Artificial Intelligence, Faculty of Electrical & Electronics Engineering, Ton Duc Thang University, Ho Chi Minh City, Viet Nam
A. Chandrashekar: Department of Mechanical Engineering, Bangalore Institute of Technology, Bengaluru 560004, India
Tanya Gera: Chitkara University Institute of Engineering and Technology, Chitkara University, Punjab, India; Corresponding authors.
Kottakkaran Sooppy Nisar: Department of Mathematics, College of Arts and Sciences, Wadi Aldawaser, 11991, Prince Sattam bin Abdulaziz University, Saudi Arabia; Corresponding authors.
C Ahamed Saleel: Department of Mechanical Engineering, College of Engineering, King Khalid University, PO Box 394, Abha 61421, Saudi Arabia

Journal volume & issue: Vol. 14, no. 2
p. 101853

Abstract

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Friction welding is a method of joining two materials in solid-state that have a good bonding connection. The materials are eventually joined by continuous acts of forging pressure combined with rotational drives by varying parameters such as friction pressure, forging pressure, friction time, rotation speed and upset time. Low input heat and high contact bonding were the characteristics of this process. In this present work, micro hardness and structural analyses of friction welded joints were investigated experimentally, effect of process parameters on properties and temperature distribution were evaluated using ANOVA and were compared with Finite element analysis using ANSYS R16.2. The results were in good agreement with each other. The friction time was 5 s, the rotation speed was 2100 rpm, the friction pressure was 80 MPa, and the forging pressure was 84.5 MPa, all of which were optimal process parameters, resulted in sound joints.

Published in Ain Shams Engineering Journal

ISSN: 2090-4479 (Print); 2090-4495 (Online)
Publisher: Elsevier
Country of publisher: Egypt
LCC subjects: Technology: Engineering (General). Civil engineering (General)
Website: http://www.journals.elsevier.com/ain-shams-engineering-journal/

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