TENSILE-SHEAR-STRENGTH PREDICTION OFFRICTION-MELT-BONDED DISSIMILAR SPOT JOINTS USINGRSM

Ramaswamy   Palanivel; Soundararaja Perumal  Vigneshwaran; Yousef  Alqurashi; Mohammad Abdur  Rasheed

doi:10.17222/mit.2022.689

Ramaswamy Palanivel Department of Mechanical Engineering, College of Engineering, Shaqra University, Dawadmi, Riyadh, Saudi Arabia
Soundararaja Perumal Vigneshwaran Department of Mechanical Engineering, SRM Institute of Science and Technology, Ramapuram Campus, Chennai, Tamil Nadu, India
Yousef Alqurashi Department of Mechanical Engineering, College of Engineering, Shaqra University, Dawadmi, Riyadh, Saudi Arabia
Mohammad Abdur Rasheed Department of Civil Engineering, College of Engineering, Shaqra University, Dawadmi, Riyadh, Saudi Arabia

DOI: https://doi.org/10.17222/mit.2022.689

Keywords: friction melt bonding, renewable energy, dissimilar joints, optimization

Abstract

The joining of aluminium (Al) and copper (Cu) is an essential spot weld for renewable energy applications due to its excellent thermal and electrical conductivity. It is challenging to produce a high-quality Al-Cu spot weld using traditional techniques and the durability of a weldment is also uncertain. A new welding technique that is effective and suitable for spot welding Cu and Al is friction-melt-bonding (FMB) spot welding. The process parameters employed during welding have a strong impact on the quality of a weld. The strategy for integrating the FMB process characteristics, such as tool rotational speed and dwell time, into a mathematical model that may be used for predicting the process parameters of dissimilar spot joints, was the focus of this study. The findings showed that the tensile shear fracture load (TSFL) was significantly influenced by the tool's rotational speed and dwell time. Optimization was carried out using the response surface methodology (RSM) to find the best FMB process parameters for making a dissimilar spot weld of AA 6061-Cu.

References

1. J. Y. Yong, V. K. Ramachandaramurthy, K. M. Tan, N. Mithulananthan, A review on the state-of-the-art technologies of electric vehicle, its impacts and prospects, Renewable Sustainable Energy Reviews, 49 (2015), 365385, https://doi.org/10.1016/j.rser.2015.04.130

2. M. Palanisamy, V. P. Parikh, M. H. Parekh, V. G. Pol, Lithium metal battery pouch cell assembly and prototype demonstration using tailored polypropylene separator, Energy Technology, 8 (2020) 6, 2000094, https://doi.org/10.1002/ente.202000094

3. I. Dinaharan, E. T. Akinlabi, Influence of the tool rotational speed on the microstructure and joint strength of friction-stir spot-welded pure copper, Materiali in tehnologije / Materials and Technology, 50 (2016) 5, 791–796, https://doi:10.17222/mit.2015.301

4. N. J. Mena, P. J. Jacques, L. Dinga, N. Gauquelin, D. Schryvers, H. Idrissi, F. Delannay, A. Simar, Enhancement of toughness of Al-to-steel Friction Melt Bonded welds via metallic interlayers, Materials Science & Engineering A, 740741 (2019), 274284, https://doi.org/10.1016/j.msea.2018.10.101

5. M. J. Brand, P. A. Schmidt, M. F. Zaeh, A. Jossen, Welding techniques for battery cells and resulting electrical contact resistances, Journal of Energy Storage, 1 (2015), 714, https://doi.org/10.1016/j.est.2015.04.001

6. L. C. Campanelli, U. F. H. Suhuddin, A. I .S Antonialli, J. F. dos Santos, N. G. De Alcantara, C. Bolfarini, Metallurgy and mechanical performance of AZ31 magnesium alloy friction spot welds, Journal of Material Processing Technology, 213 (2013) 4, 515521, https://doi.org/10.1016/j.jmatprotec.2012.11.002

7. T. Sapanathan, N. J. Mena, I. Sabirov, M. A. Monclús, J. M. M. Aldareguía, P. Xia, L. Zhao, A. Simar, A new physical simulation tool to predict the interface of dissimilar aluminum to steel welds performed by friction melt bonding, Journal of Materials Science & Technology, 35 (2019) 9, 2048–2057, https://doi.org/10.1016/j.jmst.2019.05.004

8. Y. Chen, H. Deng, H. Liu, T. Zhang, S. Li, S. Wang, C. Chen, A novel strategy for the reliable joining of Ti6Al4V/2A12-T4 dissimilar alloys via friction melt-bonded spot welding, Materials Letters, 253 (2019), 306309, https://doi.org/10.1016/j.matlet.2019.06.089

9. S. Crucifix, C. V. D. Rest, N. J. Mena, P. J. Jacques, A. Simar, Modelling thermal cycles and intermetallic growth during friction melt bonding of ULC steel to aluminium alloy 2024-T3, Science and Technology of Welding and Joining, 20 (2015) 4, 319324, https://doi.org/10.1179/1362171815Y.0000000020

10. N. J. Mena, A. Simar, P. J. Jacques, On the interplay between intermetallic controlled growth and hot tearing susceptibility in Al-to-steel welding with additional interlayers, Materials and Design, 180 (2019), 107958, https://doi.org/10.1016/j.matdes.2019.107958

11. R. Karthikeyan, V. Balasubramanian, Predictions of the optimized friction stir spot welding process parameters for joining AA2024 aluminum alloy using RSM, Int. J. Adv. Manuf. Technol., 51 (2010), 173–183, https://doi.org/10.1007/s00170-010-2618-2

12. A. Kadirvel, P. Hariharan, Optimization of the die-sinking micro-EDM process for multiple performance characteristics using the Taguchi-based grey relational analysis, Materiali in tehnologije / Materials and Technology, 48 (2014) 1, 27–32

13. T. Udayakumar, K. Raja, T. M. Afsal Husain, P. Sathiya, Prediction and optimization of friction welding parameters for super duplex stainless steel (UNS S32760) joints, Materials and Design, 53 (2014), 226235, https://doi.org/10.1016/j.matdes.2013.07.002

14. A. H. Plaine, A. R. Gonzalez, U. F. H. Suhuddin, J. F. dos Santos, N. G. Alcântara, The optimization of friction spot welding process parameters in AA6181-T4 and Ti6Al4V dissimilar joints, Materials & Design, 83 (2015), 36–41, http://dx.doi.org/10.1016/j.matdes.2015.05.082

15. S. T. Amancio-Filho, A. P. C. Camillo, L. Bergmann, J. F. dos Santos, S. E. Kuri, N. G. Alcântara, Preliminary investigation of the microstructure and mechanical behaviour of 2024 aluminium alloy friction spot welds, Mater. Trans., 52 (2011) 5, 985–991, https://doi.org/10.2320/matertrans.L-MZ201126