Microstructure modification of 2024 aluminum alloy produced by friction drilling

Елисеев, А. А.; Фортуна, С. В.; Колубаев, Е. А.; Калашникова, Т. А.

doi:10.1016/j.msea.2017.03.040

Cited by 72 publications

(34 citation statements)

References 11 publications

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“…Therefore, the strength of the flowed material increases when approaching the surface of the thermal friction drilled hole. 1 A bushing with a cylindrical shape, having no cracks or petal formation on it, increases the clamping load. 2 Moreover, a higher bushing length leads to a larger screwing area as well as increasing the connection strength of the sheet materials.…”

Section: Introductionmentioning

confidence: 99%

A geometrical approach to deriving a bushing height equation for thermal friction drilling

Demir¹

2019

Mater. Tehnol.

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The main purpose of thermal friction drilling is to increase the connection strength with the help of bushing formation. Therefore, the bushing formation and its geometry are of great interest. In this study, the bushing shapes obtained from the literature are analyzed geometrically according to their outer curve lines. These curve lines resemble a graph of parabola with varying slopes. The total volume of the evacuated material is completed when the tool cylindrical region sinks into the workpiece (t) mm in depth. It is accepted that approximately by the time when the tip of the tool reaches the half thickness of the material, the evacuated material forms a flake. By subtracting the flake volume (VC) from the total evacuated-material volume (VE), the volume of the bushing shape (VB) is determined. From the obtained equation, the bushing height is found, depending on the hole diameter (d), sheet-material thickness (t), tool conical angle (b), feed rate (f), which can be selected by the operator, and also equation constant μ. Using the bushing-height values, gained from the literature, the limit of the constant is specified as 0.001 £ μ £ 1.2 for thermal friction drilling of all kinds of materials. By comparing the experimental bushing-height results, obtained from the literature, with the modeling data, it is observed that the equation constant (μ) shows a simultaneous alteration with the material thickness (t), hole diameter (d) and tool conical angle (b), but an adverse alteration with the feed rate (f).Glavni namen termi~nega tornega vrtanja je pove~anje vezne trdnosti med osnovnim materialom in med vrtanjem za vrtino nastalo posebno obliko (blazinico). Zato sta nastanek te blazinice za vrtino in njena geometrija zelo zanimiva. Avtorji geometri~no analizirajo blazinice, nastale po tornem vrtanju, glede na njihov zunanji obris. Podatke o njihovih geometrijah so zbrali v podani literaturi. Obrisi nastalih blazinic spominjajo na parabole z razli~nim nagibom. Pretvorba izvrtanega materiala v blazinico se zaklju~i, ko se cilindri~ni del vrtala potopi v material za globino (t) v mm. Splo{no je sprejeto, da dokler konica vrtala ne dose`e pribli`no polovice debeline materiala, izvrtani material tvori obliko ostru`ka. Z od{tevanjem volumna ostru`ka (VC) od celotnega volumna (VE) lahko izra~unamo volumen nastale blazinice (VB). Vi{ino nastale blazinice lahko tako izra~unamo v odvisnosti od premera vrtine (d), debeline materiala (t), kota konice vrtala (b), hitrosti prodiranja vrtala v material (f), ki jo dolo~i/izbere operater na stroju in konstante μ. Iz podatkov, zbranih v literaturi za nastale vi{ine blazinic, ima konstanta vrednosti med 0.001 £ μ £ 1.2 za termi~no vrtanje vseh vrst materialov. Primerjava eksperimentalnih rezultatov za vi{ino blazinice, dobljenih v literaturi, z modelnimi podatki ka`e, da je konstanta (μ) isto~asno odvisna od debeline materiala (t), premera vrtine (d), koni~nosti konice vrtala (b), medtem ko ima hitrost prodiranja vrtala v material (f) obraten u~inek. Klju~ne besede: termi~no torno v...

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Section: Introductionmentioning

confidence: 99%

A geometrical approach to deriving a bushing height equation for thermal friction drilling

Demir¹

2019

Mater. Tehnol.

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“…The excessive tool wear in friction drilling of difficult-to-machine materials shows why a fundamental study on tool condition and microstructural analysis of tool wear for different workpiece materials is needed for further development. Due to the importance of excessive heat generation, which is close to the melting point, and high plastic strain, Eliseev et al [17] and Lee et al [11] highlighted the necessity of studying microstructural changes to investigate effects of workpiece material properties, heat generation, and plastic strain. In addition, Ozek and Demir [18,19] showed that microstructural analysis assists in examining the effects of different spindle speeds and feed rates on surface roughness, plastic strain distribution, and cracks on drilled holes.…”

Section: Introductionmentioning

confidence: 99%

“…However, at high spindle speed the drilling tool coating increases heat generation and increases tool wear. Elissev et al [17] carried out experiments to investigate modification of the AA2024 microstructure produced by friction drilling. They characterized the different zones of materials around the drilled-hole.…”

Section: Introductionmentioning

confidence: 99%

Friction Drilling of Difficult-to-Machine Materials: Workpiece Microstructural Alterations and Tool Wear

Dehghan

Ismail

Ariffin

et al. 2019

Metals

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Difficult-to-machine materials are metals that have great toughness, high work-hardening, and low thermal conductivity. Friction drilling of difficult-to-machine materials is a technically challenging task due to the difficulty of friction drilling, leading to excessive tool wear, which adversely affects surface integrity and product performance. In the present study, the microstructural changes of workpieces and tool wear for friction drilling of AISI304, Ti-6Al-4V, and Inconel718 are characterized. It helps to have an in-depth understanding of heat generation mechanics by friction and the mechanism of the friction drilling process. The study contributes to providing an enhanced microstructural characterization of workpiece and tool conditions, which identifies the material behavior and shows how it affects the bushing formation quality and drilling tool performance. The results reveal that the abrasive wear is mostly observed in the conical region of the tool, which has maximum contact with hole-wall. Moreover, the low thermal conductivity of Ti-6Al-4V increases frictional heat generation severely, and reduces product quality and tool life subsequently.The term "difficult-to-machine materials" refers to metals that have unique metallurgical properties, such as great toughness, high work-hardening, and low thermal conductivity. A wide range of applications for difficult-to-machine materials can be found in industry, from automotive to aerospace, and from nuclear to medical. The performance of these materials in machining makes them interesting for researchers [10]. Chow et al. [4] claimed that the attractive advantages of austenitic stainless steel AISI304 are excellent corrosion resistance, a high work-hardening rate, modest thermal conductivity, high temperature oxidation, and good formability. Later, Lee et al. [11] demonstrated that this material usually is accompanied by low productivity, poor surface quality, and short tool life. The wide applications of nickel-based alloy Inconel718 in high temperature conditions with creeping, corrosion, and thermal shock resistance encouraged Yang et al. [12] to bring up its usage in extreme environments, such as aerospace and aircraft industries, gas turbine blades, seals, and jet engines. Shokrani et al. [13] completed a survey on the applications of some difficult-to-machine materials, including austenitic stainless steel AISI304, titanium alloy Ti-6Al-4V, and nickel-based alloy Inconel718 in different fields. In a previous study [14], Zhu et al. considered the application of Ti-6Al-4V, which is readily regarded as a difficult-to-machine material, in the aircraft industry due to the good compromise between mechanical resistance and tenacity, together with its low density and excellent corrosion resistance. Therefore, one might say that the most significant issues addressed in friction drilling of difficult-to-machine materials are product quality and tool life.The process of friction drilling involves six different stages, as shown in Figure 1. At the beginning, the...

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“…A new alternative rapid and economical method to obtain joints of different metals and alloys is friction drilling [14][15][16]. This is based on the material flow, by using the heat caused by the friction of a conical shape rotary tool without cutting edges [17].…”

Section: Introductionmentioning

confidence: 99%

“…This is based on the material flow, by using the heat caused by the friction of a conical shape rotary tool without cutting edges [17]. Authors [16] investigated the microstructure modification of 2024 aluminum alloy produced by friction drilling. They showed that the physical processes and the final structure are the same as friction stir welding terminology.…”

Section: Introductionmentioning

confidence: 99%

Effect of Pulse Laser Welding Parameters and Filler Metal on Microstructure and Mechanical Properties of Al-4.7Mg-0.32Mn-0.21Sc-0.1Zr Alloy

Логинова

Khalil

Поздняков

et al. 2017

Metals

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Abstract:The effect of pulse laser welding parameters and filler metal on microstructure and mechanical properties of the new heat-treatable, wieldable, cryogenic Al-4.7Mg-0.32Mn-0.21Sc-0.1Zr alloy were investigated. The optimum parameters of pulsed laser welding were found. They were 330-340 V in voltage, 0.2-0.25 mm in pulse overlap with 12 ms duration, and 2 mm/s speed and ramp-down pulse shape. Pulsed laser welding without and with Al-5Mg filler metal led to the formation of duplex (columnar and fine grains) as-cast structures with hot cracks and gas porosity as defects in the weld zone. Using Al-5Ti-1B filler metal for welding led to the formation of the fine grain structure with an average grain size of 4 ± 0.2 µm and without any weld defects. The average concentration of Mg is 2.8%; Mn, 0.2%; Zr, 0.1%; Sc, 0.15%; and Ti, 2.1% were formed in the weld. The ultimate tensile strength (UTS) of the welded alloy with AlTiB was 260 MPa, which was equal to the base metal in the as-cast condition. The UTS was increased by 60 MPa after annealing at 370 • C for 6 h that was 85% of UTS of the base alloy.

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Microstructure modification of 2024 aluminum alloy produced by friction drilling

Cited by 72 publications

References 11 publications

A geometrical approach to deriving a bushing height equation for thermal friction drilling

A geometrical approach to deriving a bushing height equation for thermal friction drilling

Friction Drilling of Difficult-to-Machine Materials: Workpiece Microstructural Alterations and Tool Wear

Effect of Pulse Laser Welding Parameters and Filler Metal on Microstructure and Mechanical Properties of Al-4.7Mg-0.32Mn-0.21Sc-0.1Zr Alloy

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