Friction hydro-pillar processing (FHPP) is a novel technique that involves solid-state joining of an external plug onto a substrate by plastic deformation. A systematic investigation on material flow during FHPP is required but rarely reported. The present work reports a coupled theoretical and a three-dimensional X-ray computer tomography-based experimental study using a Ti-alloy as a tracer material to realise the material flow during FHPP of a AISI 4140 steel substrate. The cumulative results showed that the central portion of the plug deformed in a series of layerwise shear planes. However, the plasticised material towards the outer area of the plug flowed through the clearance between the plug and the substrate with excess volume moving out as flash.
Abstract:The friction welding process is shown as an effective alternative compared to the conventional methods of joining materials, in particular Friction Hydro Pillar Processing (FHPP). With the use of automated equipment joints are produced with reliable quality and repeatability, making it possible to follow in real time the welding process. The study of the application of this process in different materials proves its use in production systems. The development of several lines of research shows that even varying materials and geometry of joints with at least 20 mm deep in thick plates, the processing time remains less than 6 (six) minutes. Furthermore, as a result joints with suitable metal/mechanical properties are made with low production cost and high productivity, even for materials with low weldability and with different characteristics. In this work will be presented various materials joined by FHPP, as well as its advantages and applicability.
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