The present study aims to develop the numerical relationship to attain maximum tensile strength of the friction welded AISI410 MSS joints by using response surface methodology. The friction welding (FW) process parameters considered for optimization namely rotational speed, upset pressure, friction time, and upset time. The FW parameters of 31 sets have been used to manufacture the joints to attain the maximum strength. Moreover, the detail relates the optimization procedure with respect to welding conditions on AISI410 MSS joints and its optimized parameters were reported. The optimized results have been correlated with the weld interface of the specimen with reference to tensile properties, macro and microstructure features, hardness, and fracture morphology. Finally, the results concluded that the rotational speed as the most effectual process parameter on the joint properties of the FW AISI410 MSS joint.
Friction welded AA6061 matrix hybrid composite joints were investigated to understand the process effect on the metallurgical properties with the aid of empirical relationships. SiC of 10 % with the standard particle size of 25 µm and 5 % graphite with the particle size of 30 µm were added into the AA6061 matrix. The investigation has 20 sets of experiments as per the matrix designed. Each process condition, namely rotation speed (N), upset load (F), and upset time (T), as well as their impact on joint properties, were investigated individually, with the estimated tensile strength correlated to their corresponding metallographic properties. The observation of this study concludes that the disparity in grain size is mainly affected by the availability of heat sources and the plasticized material during the friction stage and it is highly influenced by rotation speed. Furthermore, the lower level parameters produce the defective joint while the higher-level parameters are attributed to ejecting the extensive amount of hot material from the joint interface. Finer reduction in grain size of 1.5 µm and ample plasticized material consolidation at the optimized welding conditions of 1600 rpm rotation speed, 3.5 kN upset load, and 4 s upset time were attributed to achieving the maximum tensile strength of 167 MPa.
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