EFFECT OF SINGLE CONE GEOMETRY OF FRICTION AREA ON TENSILE STRENGTH OF CONTINUOUS DRIVE FRICTION DISSIMILAR WELD JOINT OF ROUND BAR ALUMINIUM A6061 AND STEEL S15C

This paper reveals the tensile strength of the continuous drive friction weld (CDFW) joint of dissimilar metal between a round aluminium bar of A6061 alloy and low carbon steel S15C, which is affected by the single cone geometry of the friction area of carbon steel S15C.The geometry of a single cone on friction area of S15C steel was represented by the ratio of the small diameter (D1) and big diameter (D2) of the cone.D1 is the diameter of the friction area during friction welding.D2 is the diameter of a round aluminium bar.The D1/ D2 ratios used were 0.04, 0.44, 0.68, and 1.The smaller D1/ D2 ratio forms a sharper cone of S15C steel to rub against aluminium A6061.The burn-off length during the friction phase of CDFW was 20 mm to produce adequate flash and CDFW joint.Tensile strength test, macrostructure, and micro-hardness test were conducted.The results show that D1/ D2 = 0.04, which formed a complete cone of geometry weld, produced the maximum tensile strength of the CDFW joint, which is 190.6 MPa.It is thought that it occurs due to minimum porosity in the CDFW joint, widest area of interface between aluminium A6061 and low carbon steel S15C, and total lower burn-off length during the CDFW process that is related to the minimum heat input to produce CDFW joint.