BANHA UNIVERSITY

HIGH INSTITUTE OF TECHNOLOGY Mechanical Engineering Department Manufacturing Technology

FRICTION STIR WELDING (FSW)

Dissimilar welding of Al To stainless steel (304)

1. 2. 3. 4. 5. 6.

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8. 9.

Abu Bakr Okasha Abdullah Ahmad Abdullah Ibrahim Abdullah Sameh Maher Fouad Sherif Ismail Sedky Abdoul.Maqsoud , Maraashly Emad Soliman Mostafa Muhammad Micheal Aziz Farag Atallah Muhammad Sobhy Soliman , Elshohady Muhammad Salah Muhammad, Fayssal Mahmoud Ibrahim Ahmad Muhammad

Prepared By Group no. (6) 5th year

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2.

Is to provide a new solid-state joining process. This joining technique is energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys like Stainless steel (304) that are hard to weld by conventional fusion welding. Also our objectives of our work were to: Optimize welding conditions & parameters such as tool pin geometry, rotational speed and travel speed. Study the effects of welding parameters on microstructure evolution and mechanical properties of welded joints of dissimilar Al to Stainless Steel (304).

Experimental

 H12

Tool steel Pure Aluminum Stainless steel (304)

To use these materials in our work such operations should be done firstly

Heat Treatment
1. 2. 3. 4.

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6. 7. 8.

Setting the furnace on 850 C and put pieces of coal. Put the tool inside the furnace and setting it on 1010 C. Keep the tool inside the furnace for 45 minutes after reaching 1010 C. Take out the tool and leave it cooled in air until room temperature. First Tempering: holding it in the furnace at 550 C for 60 minutes. Take out the tool and leave it cooled again in air until room temperature. Second Tempering: holding it in the furnace at 550 C for 60 minutes. Take out the tool and leave it cooled in air.

1. 2. 3. 4.

Process characteristics
Reduce residual stresses. Increase hardness. Improves toughness. Increases impact resistance

H12 Tool steel

Heat treatment operation curve of tool steel H12

1200

1000
Temperature, C

800 600 400

200

0 Time, minutes

Tools geometry performed by machining operations

Type (I) Tool: Cylindrical Pin

Type (II) Tool: Squared Pin

Type (III) Tool: Tapered Pin

Type (IV) Tool: Hexagonal Pin

Pure Aluminum Stainless steel (304) To Pack away them to be used in our work some processes should be done like

Material work piece

1. Cleaning the sample mechanically using stainless steel wire brush to remove rust.

2.

Cleaning the sample using acetone to remove grease and oils.

Material work piece

3. Fixing the sample tightly on the milling machine.

4. Starting FSW process.

TESTS

 Microstructure Investigation Specimen Preparation

Cutting the specimen.

Grinding it using Al2O3 or SiC abrasive paper.

Polishing.

Etching.

Microscopy
Optical microscopy using metallographic microscopes is a

widely used technique for analyzing metallographic specimens. The typical magnification range for optical microscopes is 50 to 1000X .

Microstructure investigation of stainless steel Base metal of sample # 2

Microstructure of sample #2 at WZ/Stainless steel (304) side of joint shows sound interface between stainless steel and aluminum when using cylindrical pin tool .

Microstructure of Al/Stainless steel welded joint of sample # 8A at the interface between st.st and weld zone, shows micro cracks at the interface

Hardness
Hardness Testing provides useful information, which can be correlated to tensile strength, wear resistance, ductility, and other physical characteristics of the material. Hardness testing is therefore useful for monitoring quality control and

for aiding in the materials selection process. The working principle of Vickers hardness testers employs only one indenter, being a pyramidal diamond with square base. After the indentation is made, the two diagonals will be measured and as these are almost never the same, the average value will be considered. the Vickers number is given by the relationship between the applied load and the surface area of the indentation. In our process were 10Kg till 15 Sec.

Hardness curve of Sample #2

Hardness curve of sample # 7