M.B. Uday

Advances in friction welding process: a review

Abstract Friction welding is now well established as one of the most economical and highly productive methods in joining similar and dissimilar metals. It is widely used in automotive and aerospace industrial applications. Friction welding is often the only viable alternative in this field to overcome the difficulties encountered in joining the materials with widely varying physical characteristics. This process employs a machine that is designed to convert mechanical energy into heat at the joint to weld using relative movement between workpieces, without the use of electrical energy or heat from other sources. This review deals with the fundamental understanding of the process. The focus is on the mechanism of friction welding, types of relative motions of the process, influence of parameters, heat generation in the process, understanding the deformation, microstructure and the properties of similar and dissimilar welded materials.

Current Issues and Problems in the Joining of Ceramic to Metal

Ceramics and metals are two of the oldest established classes of technologically useful materials. While metals dominate engineering applications, ceramics have some attractive properties compared to metals, which make them useful for specific applications. The properties of individual ceramics and metals can vary widely; however, the characteristics of most materials in the two classes differ significantly. Joints between a metal and ceramic are becoming increasingly important in the manufacturing of a wide variety of technological product. But joining ceramics to metallic materials often remains an unresolved or unsatisfactorily resolved problem. This chapter deals with problems of various studies in recent years on the joining between two materials.

Effect of Deformation Behavior on the Grain Size of the 6061 Aluminum Alloy Joint with Alumina by Friction Welding

Friction welding is widely used as a mass-production method in various industries. Joining of ceramic-metal is one of the most essential needs of many industrial applications. Experiments were performed to observe the deformation characteristics of 6061 aluminum alloy after joining with alumina using friction-welding process at different rotational speeds and to relate difference in grain size with differences in deformation behavior. In the present study, electron microscopy and X-ray diffraction profile analysis were used to study the effect of plastic deformation of interface material on the grain size of 6061 aluminum alloy when there is a joint with the ceramic. The effect of rotation speed and the degree of deformation appeared to be high on the 6061 Al alloy than on the ceramic part. Results showed different deformation mechanisms at different rotational speeds and confirmed unambiguously the change in crystalline grains as a result of deformation mechanisms.