Parametric Investigation of Friction Crush Welding of Two Dissimilar Metals – Aluminium 6061 T-6 and Low Carbon Steel AISI 1016

Abstract In the present work, a newly developed Friction Crush Welding (FCW) process is explored for joining Aluminum 6061 T-6 and low carbon steel AISI 1016 without the use of any filler material. The method involves a friction interaction between a non-consumable rotating tool and the similar or dissimilar workpiece surfaces. The process parameters such as tool profile (spherical, trapezoidal, and elliptical), tool rotation speed (2000 rpm, 4000 rpm, and 6000 rpm), and welding speed (15mm/min, 30mm/min, and 45mm/min) were explored and optimized. A vertical milling machine was used for carrying out the experimentation. In order to perform friction crush welding, the work parts were appropriately fastened using the appropriate clamps, maintaining the necessary space between the two dissimilar materials. Following the experiments, specimens were cut as per the ASTM standards and tensile and hardness tests were performed to determine tensile strength and hardness values. The effect of tool profile, tool speed, and feed rate on joint hardness and tensile strength were investigated. The maximum tensile strength of 170 MPa was attained at 6000 rpm and a feed rate of 15 mm/min using a trapezoidal tool profile. Tool rotation has been identified as the most influential component in boosting bond strength.