International Journal of Mechanical Engineering and Technology (IJMET) Volume 10, Issue 01, January 2019, pp. 1751-1761, Article ID: IJMET_10_01_174 Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=01 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 © IAEME Publication Scopus Indexed BEHAVIOUR OF THREADED CYLINDER TOOL IN THE FRICTION STIR WELDING OF AL-ZRB2 AND AL-SIC COMPOSITE P. Jayaseelan and T. V. Christy*. Department of Mechanical Engineering, School of Engineering & Technology, Karunya Institute of Technology and Sciences, Karunya Nagar, Coimbatore – 641114, India *Corresponding author ABSTRACT Friction Stir welding is a solid state joining process of using without any filler material. In this work, two base materials likely Al-MMC’s are used namely Silicon Carbide and Zirconium di-Boride are used. Hardness Rockwell Value and Tensile Strength Tests are evaluated to the various tool material respect to Al-ZrB2 and Al-SiC. Threaded Cylinder Tool made of the materials likely OHNS, HCHCr, H13 are carried out in the process with D/d Ratio are used. The process is carried out with three different tool materials and two different base material mainly aluminium reinforced Zirconium diboride (Al-ZrB2) and Silicon Carbide (Al-SiC). The Micrograph of each four zones for the tool material and base material is shown. This paper mainly focusing on which the tool material shows a maximum tensile and hardness value for two base materials. Keywords: Friction Stir Welding; Threaded Cylinder; Tool Material; Al-ZrB2, Al-SiC D/d Ratio. Cite this Article: P. Jayaseelan and T. V. Christy, Behavior of Threaded Cylinder Tool in the Friction Stir Welding of Al-Zrb2 and Al-Sic Composite, International Journal of Mechanical Engineering and Technology, 10(01), 2019, pp.1751–1761 http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&Type=01 1. INTRODUCTION Friction Stir Welding is initially developed by “The Welding Institute” (TWI) in December 1991. Friction Stir Welding is a Solid state joining process that creates a frictional heat between the plates or where the tool is plunged. The poor welds are caused by detrimental phases can be avoided in this type of welding. Tool plays a major part in the non-consumable welding process. By the rotational of the tool, plastic deformation occurs between the contact surfaces. Tool geometry, tool profile, and tool material are plays an important role in completing the successful welded joints. The four main process parameter includes speed of the rotation, traverse speed, plunging depth and tilt angle. The length of the tool is slightly smaller than the thickness of the plates. Especially, Friction stir welding is originally adapted for welding the Aluminium alloys. http://www.iaeme.com/IJMET/index.asp 1751 editor@iaeme.com P. Jayaseelan and T. V. Christy This welding process does not require any filler material. According to the macro view, the four different zones are classified and considered. They are unaffected zone or Base metal (BM), HeatAffected zone (HAZ), Thermo-mechanically heat affected zone (TMAZ), and stirred zone (SZ) or Nugget Zone (NZ). Basically Zones are divided by its microstructure and temperature variations. Especially, the Weld Zone has higher amount of temperature compared to the Thermomechanically affected zone. Then, the thermos-mechanically affected zone has higher temperature than over the other and so on. Each zones having the different microstructure properties and strength. Here, this process is mainly focused on the Aluminium reinforced Silicon Carbide and Zirconium diboride are mainly focused with three different threaded tool material known as H13, OHNS, HCHCr. D/d ratios and process parameter are assessed and tabulated. Comparing the strength between the Al-SiC and Al-ZrB2 are shown in the following tables. 2. EXPERIMENTAL PROCEDURE: 2.1. Friction Stir Welding Tool Friction stir welding tool consists of round shoulder and pin was used. Basically pin will have the factor of different profiles such as threaded, tapered, conical etc...So selecting the proper tool for the base material is a play. Proper design and dimensions should be followed then the profile was to be done accordingly. Proper selection of tool will provides a proper weld quality. Rotating shoulder along with the pin is fixed into the CNC machine and operated numerically. Selection of appropriate tool and tool design plays an important role in the FSW process. In this case, we used the Threaded Cylindrical tool as shown in Figure 1. 2.2. Tool Material Used FSW tool plays an important role and selection of tool material achieves proper weld quality and long-durable purpose. For this study we discussed H13, OHNS, and HCHCr for the Al-ZrB2 and Al-SiC. Selecting good material for the tool will have high durability than the other material. Using tool material, should withstand the peak temperature of the welding process, so that the welding process can be done. The FSW process only done, if the tool withstand from thermal properties. Comparing one tool material with other materials should be done, so that we came to know that which material exhibits the high strength. The tool should be designed with all this concern including its material, mechanical and thermal properties. In this case, we using the three various tool profiles are Oil Hardened Normalized Steel (OHNS), High Carbon High Chromium steel (HCHCr) and H13 Steel. According to K Palani, C Elanchezhian, Karanam Avinash, C Karthik, Karra Chaitanya, Karthick Sivanur, K Yugandhar Reddy shows that, the nonconsumable FSW tool was designed based on the requirements with the dimensions of shoulder diameter and prolonged pin diameter. 2.3. Choice of Tools In this case, we used three different non-consumables tool materials was used to find out the amount of deformation and at the end of the process, proper weld should be obtained only if the grains are uniformly distributed. Here the three different tool materials used are i) High Speed Steel (H13 steel), ii) Oil Hardened Normalized Steel (OHNS), iii) High Carbon High Chromium steel (HCHCr) are tool materials carried out in the FSW process to find out which tool material and profile possess in such a way of equally distributed grains in the microstructural characterization. The tool is designed in such a way that followed by the shoulder diameter to the prolonged pin diameter in terms of D/d ratio.The following Table 1.shows the tool profile, tool material and corresponding D/d ratio are shown as below. http://www.iaeme.com/IJMET/index.asp 1752 editor@iaeme.com Behavior of Threaded Cylinder Tool in the Friction Stir Welding of Al-Zrb2 and Al-Sic Composite Table 1. Shows Tool Profile, Tool Material, D/d Ratio Tool no. 1 2 3 Tool Profile Tool Material D/d ratio Threaded Cylinder Threaded Cylinder Threaded Cylinder H13 OHNS HCHCr 2 3 4 2.4. Process In this process, the material used was Aluminium metal matrix composites (MMC’s) Al-10% ZrB2 and SiC with the dimension of the plates are 100 mm x 50 mm x 6 mm manufactured by insitu stir casting process was employed as weldments for the Friction stir welding. The enforcements such like Aluminium reinforced with Zirconium diboride and Silicon Carbide is known for improved wear resistance and tensile strength but reduced corrosion resistance. As we know that, FSW basically a welding technique for welding the Aluminium and MMC’s due to withstand the high melting point, hardness and stability. The microstructure of Al-ZrB2 and AlSiC is shown in Figure 3 and 2. According to K Palani, C Elanchezhian, K H V Saiprakash, K Sreekanth, Dayanand, Keshav Kumar, Deepak Kumar that the better microstructural results were observed in friction stir processing joints relate to the friction stir welded joints and the addition of nanoparticles improved the surface and joint properties and also they discussed Aluminium alloys in addition to nanoparticle Al2O3 and SiC showed the sound defect free joints compared to other joints. Proper selection of tool material is necessary so that we obtain a good quality of welds. Figure 1 – Threaded Cylinder 1 – H13, 2 – OHNS, 3 – HCHCr Figure 2 – Optical Micrograph of Al-ZrB2 http://www.iaeme.com/IJMET/index.asp 1753 editor@iaeme.com P. Jayaseelan and T. V. Christy 2.5. Parameter Used Welding parameters used in this case are shown in table 3. Parameter includes downforce or axial load, rotational speed, tilt angle and traverse speed. Here 1000 rpm, 25 mm/min, 3.8-4.3 kN were applied and used in this process. By the parameters used, H13 showed the superior results when compared to the other two tools materials. In general, parameters plays an important role in defect free joint, as the nominal parameters should use for obtain the good quality weld. Figure 3 – Optical Micrograph of Al-SiC Table 2 Shows Tool Configuration Factor 1 Factor 2 Factor 3 Response 1 Run A:Profile B:Material C:D/d Selected Tool 1 3 2 1 1 2 2 2 2 2 3 1 2 3 3 Figure 4 – FSW Welded Al-ZrB2 and Al-SiC with corresponding tool Used 3. EXPERIMENTAL PROCEDURE: 3.1. Mechanical Characterization Tests like Tensile strength and Hardness test are conducted to the friction stir welded specimens are Al-SiC, Al-ZrB2 are prepared as per ASTM E08 standard. Tensile tests are conducted as per the standard and concludes the results in MPa for both the specimen. Comparing the results with other tool materials H13 has a maximum strength than the OHNS and HCHCr. The D/d ratios are tabulated in the table 1. Table 4 and 5 represents the Tensile Strength for the both Specimens AlSiC and Al-ZrB2 are shown. Comparing the results, the higher strength obtained to the H13 tool material as 150 and 117 MPa for the Al-SiC and Al-ZrB2. Thus, H13 proven that possess higher strength to Al-SiC and Al-ZrB2 than the other two tool materials. Rockwell Hardness test was http://www.iaeme.com/IJMET/index.asp 1754 editor@iaeme.com Behavior of Threaded Cylinder Tool in the Friction Stir Welding of Al-Zrb2 and Al-Sic Composite evaluated for the specimens known to be Al-SiC and Al-ZrB2 respectively are conducted. The welded specimens with three different tool materials are tabulated in the table 5. Comparing with other tool material, H13 possess higher hardness value in terms with both the Al-SiC and AlZrB2. Rockwell Hardness value of tool material H13 for Al-SiC is 41 and Al-ZrB2 is 40. Other tool materials possess lower hardness value than the H13. Hence, H13 provides higher hardness value for both the base materials. Table 3 shows Parameters used in the process Sl.No Tool Rotation (in rpm) Traverse Speed (mm/min) Axial load Applied (kN) Run 1000 25 3.8 – 4.3 Table 4 shows Tensile Strength of Al – ZrB2 and Al-SiC in MPa Sl.No 1 2 3 Tool Profile Threaded Cylinder Threaded Cylinder Threaded Cylinder Tool Material H13 OHNS HCHCr Al-SiC 150 121 93 Al-ZrB2 117 80 69 Table 5 shows Rockwell Hardness Value (HRA) of Al-ZrB2 and Al-SiC Sl.No 1 2 3 Tool Profile Threaded Cylinder Threaded Cylinder Threaded Cylinder Tool Material H13 OHNS HCHCr Al-SiC 41 31 24 Al-ZrB2 40 35 34 3.2. Metallurgical Characterization According to Mohd Atif Wahid, Arshad Noor Siddiquee, Zahid A. Kahn, Nidhi showed that Due to high heat experienced during the FSW, the degree of deformation of thermal softening of materials gets increased leading to high level of plastic deformation as compared to UFSW and CFSW. The Micrographs for the four different welded zone are shown in the figure 6 and 7 for Al-SiC and Al-ZrB2 is shown. Here, four zones such as Parent Metal (PM) Zone, Heat Affected zone (HAZ), thermos-mechanically affected zone (TMAZ) and weld nugget zone (WNZ) are denoted for each micrographs termed as two different base material (Al-SiC and Al-ZrB2). The term weld nugget zone is known to be welded zone which the temperature is more in this area. The strength should be more than that of base material in the nugget zone and that fulfils the condition of the Al-SiC and Al-ZrB2 only if the H13 tools was used. The microstructure of the welded zone using H13 tool is shown in figure 6 and 7. In this case, parent metal and weld nugget zone are satisfies the condition rather than OHNS and HCHCr. The run in each cases used are 1000 rpm, 25 mm/min were used in both the cases. The presence of finer grain particles were obtained without any defects only in the case of H13 tool material. The non-uniform distribution of grain particles and insufficient breaking of the reinforcements are obtained by using other tool materials. Using the Al-SiC with H13 shows a superior prior results in the microstructure changes as compared to Al-ZrB2. Evaluated results are shown and when comparing with H13 tool shows a superior tensile strength and hardness value when compared to other two tools. As we can see that the defect free joint is obtained using the H13 threaded cylindrical tool, shows a superior tensile strength, and Hardness value in both the cases. The macrostructure and values are compared as shown in figure 5. http://www.iaeme.com/IJMET/index.asp 1755 editor@iaeme.com P. Jayaseelan and T. V. Christy Figure 5 – Macrostructure of Welded Joints Figure 6 - Micrographs of Al-ZrB2 composites welded using tool no.1 - H13, threaded cylinder pin http://www.iaeme.com/IJMET/index.asp 1756 editor@iaeme.com Behavior of Threaded Cylinder Tool in the Friction Stir Welding of Al-Zrb2 and Al-Sic Composite Figure 7 – Micrographs of Al-SiC composites welded using tool no.1 - H13, threaded cylinder pin Figure – 8 Micrographs of Al-ZrB2 composites welded using tool no 2 – OHNS, threaded cylinder pin http://www.iaeme.com/IJMET/index.asp 1757 editor@iaeme.com P. Jayaseelan and T. V. Christy Figure – 9 Micrographs of Al-SiC composites welded using tool no 2 – OHNS, threaded cylinder pin Figure 10 Micrographs of Al-ZrB2 composites welded using tool no 3 – HCHCr, threaded cylinder pin http://www.iaeme.com/IJMET/index.asp 1758 editor@iaeme.com Behavior of Threaded Cylinder Tool in the Friction Stir Welding of Al-Zrb2 and Al-Sic Composite Figure 11 Micrographs of Al-SiC composites welded using tool no 3 – HCHCr, threaded cylinder pin 4. CONCLUSION After completing of the welding process with three different tool materials and two different base materials comparing with the values in terms of strength and hardness, the following results are concluded. Friction stir welded using H13 Threaded cylindrical tool possess higher Ultimate tensile strength (UTS) of 150 and 117 MPa comparing with other two tools namely, OHNS threaded cylinder and HCHCr threaded cylinder for in both cases of Al-SiC and Al-ZrB2 respectively When examined with Rockwell Hardness test (HRA) welded with H13 Threaded cylindrical tool which possess higher value of 41 and 40 comparatively with other two tools for both cases in Al-SiC and Al-ZrB2 respectively. Studying the Micrographs of Al-SiC and Al-ZrB2 showing that welded using threaded H13 tool cylinder pin showing quality welded joints. For both the Al-SiC and Al-ZrB2 welded with H13 threaded cylinder showing the maximum results in the case of tensile strength, hardness test and also micrographs. 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